Miller Electric 172 M-10 Gun manual

Millermatic Challen ger 172 And M-10 Gun Processes Description R MIG (GMA W) Flux Cored (FCAW) Wire Feeder OM-1318 187923F March 2000 Visit our website at www.MillerWelds.com[...]

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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

The following terms are used interchangeably throughout this manual: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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OM-1318 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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. . Means “Note”; not safety related. This group of symbols means W arning! Watch [...]

OM-1318 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 of f 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 Z49.1 and Z[...]

OM-1318 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. F [...]

OM-1318 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. However , after examining more than 500 studies spanning 17 years[...]

OM-1318 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 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. Y Identifie un message de s é curit é particulier .[...]

OM-1318 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. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans l[...]

OM-1318 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. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger [...]

OM-1318 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.S. Government Printing Of fice, W ashington, D.C. 20402. Recommended Safe Practice for t[...]

OM-1318 Page 9 SECTION 2 – SPECIFICA TIONS 2-1. Specifications Rated W elding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 230 V , 60 Hz, Single-Phase KV A KW W eight W/ Gun Overall Dimensions 130 A @ 20 V olts DC, 30% Duty Cycle 40 – 170 30 19.4 (0.28)* 4.49 0.86* 3.83 0.043* 80 lb (36 kg) Length: [...]

OM-1318 Page 10 2-3. W elding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 m i n- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycl[...]

OM-1318 Page 1 1 SECTION 3 – INST ALLA TION 3-1. 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 1 2 3 4 5 6 Ref. ST-025 190-D T ools Nee d e d : 3/8, 7/16 in 3-2. Installing Welding Gun And Changing Polarity 1 Drive Assembly 2 Gun Securing Bolt 3 Gun End Loos[...]

OM-1318 Page 12 3-3. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other station- ary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Ins[...]

OM-1318 Page 13 3-4. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 20 Normal Operating 3 30 Min Input Conductor Size In A WG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conduct[...]

OM-1318 Page 14 3-6. 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. T ools Needed: Standard Wire Reel Part No. 183 312 Part No. 135 615[...]

OM-1318 Page 15 3-7. Installing Drive Roll, Wire Guide And Threading Welding Wire 1 Drive roll Choose correct drive roll for wire type, and align drive roll with flat spot on shaft. Slide drive roll onto shaft and secure with screw . 2 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of[...]

OM-1318 Page 16 3-8. W eld Parameter 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* –– –– 3 3 2 2 1 1 .023 Wire Speed –– –– 65 60 55 50 50 40 E70S-6 V oltage T a p* 4 3 3 3 2 2 1 1 CO 2 2[...]

OM-1318 Page 17 SECTION 4 – OPERATION 4-1. Controls 1 Wire Speed Control Use control to select a wire feed speed. A s V oltage switch setting in- creases, wire speed range also in- creases (see weld setting label in welding power source). Ref. ST-187 921 2 4 1 3 2 V oltage Switch . Switch must “ click ” into detent position 1, 2, 3, or 4 for [...]

OM-1318 Page 18 SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. during heavy service, clean monthly . Or Remove drive roll and apply light coat[...]

OM-1318 Page 19 5-4. Cleaning Or Repairing Drive Assembly Y T urn Off power before cleaning or repairing drive assembly . 1 Wire Spool 2 Nozzle Cut welding wire off at nozzle. Re- tract wire onto spool and secure. 3 Pressure Roll Arm 4 Cotter Pin 5 Pin 6 Screw 7 Bearing Remove bearing. Install new bear- in g and secure with screw . Reinstall ar m o[...]

OM-1318 Page 20 5-6. Cleaning Or Replacing Gun Liner Ref. ST-802 399-A 3/8 i n Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tight- en two full turns more. Cut liner of f so that 3/4 in (19 mm) sticks out of h[...]

OM-1318 Page 21 5-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 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). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to[...]

OM-1318 Page 22 5-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not run. Replace building line fuse or reset circuit breaker if open (see Section 3-5). Secure gun trigger plug in receptacle (see Section 3-2). Place Power switch in On position (see Sect[...]

OM-1316 Page 23 SECTION 6 – ELECTRICAL DIAGRAM SB-210 034 Figure 6-1. Circuit Diagram[...]

OM-1318 Page 24 SECTION 7 – MIG WELDING (GMA W) GUIDELINES 7-1. 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. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shieldi[...]

OM-1318 Page 25 7-2. 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 .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere) .12[...]

OM-1318 Page 26 7-3. 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electrode[...]

OM-1318 Page 27 7-4. 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. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STICKO[...]

OM-1318 Page 28 7-5. 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 . NOTE 1 Stringer Bead – Steady Movement Along Seam 2 Weave Bead – Side T o Side Movement Along[...]

OM-1318 Page 29 7-8. 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use [...]

OM-1318 Page 30 7-1 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. Joint preparation and design must provide access to bottom of groove while maintainin[...]

OM-1318 Page 31 7-14. 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. Unsteady hand. Support hand[...]

OM-1318 Page 32 7-16. 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Circui[...]

OM-1318 Page 33 Notes[...]

OM-1318 Page 34 SECTION 8 – P ARTS LIST . Hardware is common and not available unless listed. Figure 8-1.Complete Assembly 2 3 4 5 6 Includes Items 7 – 12 1 13 14 7 8 9 10 11 12 15 17 16 18 19 20 21 22 23 24 25 27 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 44 55 56 57 58 59 60 61 ST-801 996-A 63 63 62[...]

OM-1318 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Complete Assembly Quantity 1 126 838 DRIVE ASSEMBL Y , wire (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 090 416 PIN, hinge 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-1318 Page 36 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Complete Assembly Quantity 56 026 843 INSULA T OR, vinyl 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1 1 1 644 BUSHING, strain relief .370/.430 ID 1 . . . . . . . . . . . . . . . . . . . . .[...]

OM-1318 Page 37 Quantity Description Part No. Item No. Figure Figure 8-2. M-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP , contact scr .023 wire x 1.125 . . . . . . . . 2 ♦ 000 067 TIP , contact scr .030 wire x 1.125 [...]

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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 adquarte rs – USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F AX: 920-735-4134 Int ernational F AX: 920-735-4125 European Headqua rters – Unit[...]