Miller Electric M-10 Gun Maintenance &TROUBLESHOOTING, Routine Maintenance, Overload Protection

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.A complete Parts List is available on-line at www.MillerWelds.com

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

						Y Disconnect power	. Maintain more often
						before maintaining.	during severe conditions.

n = Check	Z = Change	~ = Clean	l = Replace
* To be done by Factory Authorized Service Agent

Every

3 Months

l Unreadable Labels

~ Weld Terminals

nl Weld Cables

Every

6 OR

Months

~Inside Unit

Reference

6-2. Overload Protection

1

1 Supplementary Protector CB1

CB1 protects unit from overload. If CB1 opens, unit shuts down.

Reset supplementary protector.

802 441

6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, cycle unit power off and back on again.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.

OM-225 311 Page 36

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Contents OM-225 311C ProcessesDescription File MIG GmawFrom Miller to You Table of Contents − Maintenance &TROUBLESHOOTING − Parts ListSymbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explosionFlying Metal can injure eyes Buildup of GAS can injure or killCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux UNE Décharge Électrique peut entraîner la mortIndique un message de sécurité particulier LE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut SUR DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaques− Specifications SpecificationsVAC Model VAC Model w/Auto−SetEDuty Cycle And Overheating 115 VAC Model230 VAC Model OverheatingVolt-Ampere Curves AmperageInstalling Welding Gun − InstallationIncorrect Process/Polarity Table Work Cable Routing Inside UnitChanging Polarity Installing Gas Supply Special installation may be Required where gasoline orVolatile liquids are present − See NEC Article 511 or CECDo not move or operate unit where it could tip Installing Wire Spool And Adjusting Hub Tension Electrical Service Guide For 230 VAC ModelInput Voltage 230 Input Amperes At Rated Output Threading Welding Wire Remove gun nozzle and contact tipCut Off End Of Wire Open Pressure Assembly Knob Removing MIG Gun From Welding Power SourceEnd Of Wire To Spool Installing Optional Spool Gun Switch In Welding Power Source OperationConnecting Spool Gun To Millermatic 140/180 − Operation Controls For 115 VAC Model w/Auto-SetEControls For 115 VAC Model 115VControls For 230 VAC Model 230VOM-225 311 Weld Parameter Chart For 115 VAC Model w/Auto−SetE 10/90 10/65 10/80 10/60 10/50 10/95 10/75 10/100 030 0.8 mm 035 0.9 mm Aluminum 100% Argon 4043ER10/32 OM-225 311 10/90 10/45 10/60 10/30 10/32 10/80 030 0.8 mm 035 0.9 mm#220179 #220179 #202926Dcep Dcen 100 10/60 10/45 10/40 10/20 10/50 024 0.6 mm #220179 030 0.8 mm #202926 035 0.9 mm 045 1.2 mm− Maintenance &TROUBLESHOOTING Routine MaintenanceOverload Protection Drive Motor ProtectionTurn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Disconnect gun from unit Cleaning Or Replacing Gun LinerTo Reassemble Gun Replacing Switch And/Or Head Tube Troubleshooting Table Trouble RemedyOM-225 311 − Electrical Diagram Circuit Diagram234 419-B − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsTypical MIG Process Control Settings Wire Recommendation Wire SpeedSelect Wire Size Select VoltageHolding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Good Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterPossible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Excessive PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Application Common MIG Shielding GasesFlat & Horizontal1 Fillet − Parts List Recommended Spare PartsOptional Drive Rolls OptionsPage Service SupportOwner’s Record Miller Electric Mfg. Co

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