Miller Electric M-25 User's Manual
Contents
1. dl 2 Remove switch housing Install new switch and connect leads polarity is not important Reassemble in reverse order If replacing head tube continue to end of figure 4 Tools Needed C ee 3 8 3 4in 5 Loosen jam nut Remove from vice and turn head tube out by hand 7 Place head tube in vice and tighten until 6 Install existing shock washer onto new head tube Hand tighten head tube into cable connector DUIS CIE tight 0 8 Remove from vice Reposition handle and install switch housing Secure with handle locking nut 9 B E Ref 800 795 D OM 227 796 Page 7 5 3 Routine Maintenance A Turn Off welding power source and disconnect gun before maintaining Each Spool Of Wire Clean Blow Out Nozzle 2 Gun And Check Casing Contact Tip md 3 Months Replace Cracked gt Control gt Y Gas Parts Cord Hose 5 4 Troubleshooting wer Trouble Remedy Wire does not feed wire is not ener gized wire feeds unevenly Check contact tip Check for kinks in gun cable Check gun trigger plug connection at welding power source wire feeder Check and if necessary replace gun trigger switch see Section 5 22. Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
3. Check contact tip Check for kinks in gun cable Blow out liner and gun casing see Section 5 1 Weld porosity Remove weld spatter buildup in nozzle Make sure inner head tube is tight in cable connector Check shielding gas flow supply Wire feeding stops or does not feed properly during welding Straighten gun cable and or replace damaged parts see Section 5 1 Adjust drive roll pressure see wire feeder manual Change to proper drive roll groove see wire feeder manual Readjust hub tension see wire feeder manual Clean or replace liner if dirty or plugged see Section 5 1 Replace drive roll or pressure bearing if worn or slipping see wire feeder manual OM 227 796 Page 8 SECTION 6 PARTS LIST 804 467 A Figure 6 1 M 25 Gun Item Dia Part No Mkgs No Description Quantity Figure 6 1 M 25 Gun cet stu eius 200258 NOZZLE slip type 500 orf flush 1 Is wi 169 724 NOZZLE slip type 500 orf 125 recess 1 n cg S D RET 169 725 NOZZLE slip type 625 orf 125 recess 1 E 169 726 NOZZLE slip type 625 orf flush 1 xcd AAA 169 727 NOZZLE slip type 625 orf 125 stickout 1 WAA th alates he 087 299 TIP contact scr 023 wire x 1 125 O e a Seta 000 067 TIP
4. Shielding Gas 250 A With Mixed Gases Weight With 15 ft 4 6 m Power Cable 6 0 Ib 2 7 kg Identified With MI i On Power Cable 804 466 A OM 227 796 Page 3 3 2 Duty Cycle And Overheating Definition 0 gt gt 10 Minutes Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating See Section 3 1 Specifications for amperage rating and duty cycle 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 100 Duty Cycle At 200 Amperes Using CO2 100 Duty Cycle At 150 Amperes Using Mixed Gases O Continuous Welding A Exceeding duty cycle can damage unit and void warranty 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 60 Duty Cycle At 300 Amperes Using CO 60 Duty Cycle At 200 Amperes Using Mixed Gases 20 08 6 Minutes Welding 4 Minutes Resting Overheating Minutes AorV Reduce Duty Cycle sduty1 5 95 3 3 Installing Gun Pa 1 Gun Securing Knob 2 Gun End Loosen knob Insert gun end until it bottoms against drive assembly Tighten knob 3 Gun Trigger Plug Insert into receptacle and tighten threaded collar 4 Friction Terminals Some applications will require cutting off trigger plug and installing 0 250 female friction terminals onto end of leads S
5. 187 ID x 103CS rbr 1 LG vanes 227 198 x SWITCH trigger isses aed nee Ree eae eee a ut 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model is required when ordering parts from your local distributor OM 227 796 Page 10 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You 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 The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2006 Equipment with a serial number preface of LG or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FI
6. Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that
7. contact scr 030 wire x 1 125 Ds wiesen 000 068 TIP contact scr 035 wire x 1 125 E A ete 000 069 TIP contact scr 045 wire x 1 125 O E deu res 169728 ADAPTER contact tip 1 orc 169 729 ADAPTER nozzle w retaining ring 1 DL Yos bes 170468 x O RING cono Ai eee YR ee 1 puni etus 169 730 WASHER Shock sus ac A aaa EUR RC 1 xu aut ES 169 7391 5 TUBE head ic RIPE Ru E Eder Ed d pa Pa dart ore 1 OM 227 796 Page 9 Item Dia Part No Mkgs No Description Quantity Figure 6 1 M 25 Gun Continued S EE 169 738 NUT locking handle 1 E 169 732 NUT JAM 0 Ka its ne ren e ni 1 qOLS ata 221 199 HANDLE talas 1 on es 227800 CORD trigger assembly 1 qom Rim 209495 CONNECTOR feeder 1 19s ovans 079 974 O RING 500 ID x 103CS rbr 2 O ane 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 TA Sse ruse 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 A rey ets 194012 LINER monocoil 035 045 wire x 15ft consisting of 1 aos E tas 194 014 LINER monocoil 3 64 AL wire x 10ft consisting of 1 uc 152 eae 079975 O RING
8. has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVID
9. ED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you
10. KEEP AWAY UNTIL CONSULTING YOUR DOCTOR In welding as in most jobs exposure to certain hazards occurs Welding is safe when precautions are taken The safety information given below is only a summary of the more complete safety information found in the wire feeder and welding power source Owner s Manuals Read and follow all safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill ARC RAYS can burn eyes and skin 1 Always wear dry insulating gloves 1 Wear welding helmet with correct shade of filter Insulate yourself from work and ground 2 Wear correct eye and body protection Do not touch live electrode or electrical parts i 3 Cover exposed skin with spatter resistant Repair or replace worn damaged or cracked clothing gun or cable insulation z Turn off welding power source before changing HOT SURFACES can burn skin contact tip or gun parts 1 Allow gun to cool before touching Keep all covers and handle securely in place 2 Do not touch hot metal 3 Protect hot metal from contact by others NOISE can damage hearing SOME FUMES AND GASES can be hazardous APPLICATIONS SUCH AS PULSING to your health are noisy 1 Keep your head out of the fumes Check for noise level limits exceeding those 2 Ventilate area or use breathing device specified by OSHA 3 Read Material Safety Data Sheets MSDSs and Use approved ear plugs or ear
11. Miller OM 227 796A 2006 05 Processes MIG GMAW Welding A re Flux Cored FCAW Welding Ll FC Description Semi Automatic Air Cooled MIG GMAW Welding Gun MiGmatic M 25 Visit our website at www MillerWelds com OWNER S MANUAL File MIG GMAW m From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U E Bl E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do A every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of re
12. TNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders
13. ece as close to the weld as possible mod10 1 4 93 OM 227 796 Page 2 SECTION 2 SAFETY INFORMATION W Read all safety messages throughout this manual E Obey all safety messages to avoid injury W Learn the meaning of WARNING and CAUTION 1 Safety Alert Symbol 2 Signal Word WARNING means possible death 27 3 or serious injury can happen al e ELECTRIC SHOCK can kill pi CAUTION means possible minor EN Do not touch live electrical parts Keep away from moving parts injury or equipment damage can Disconnect input power before 4 Keep all panels and covers closed happen installing or servicing when operating 7 3 Statement Of Hazard And Result 5 4 Safety Instructions To Avoid Hazard E 5 Hazard Symbol If Available READ SAFETY BLOCKS at start of 6 WARNING awe Section 3 1 before proceeding 6 Safety Banner Read safety blocks for each symbol shown 7 NOTE te Turn Off switch when using high frequency 7 NOTE Special instructions for best operation not related to safety SECTION 3 INSTALLATION 3 1 Specifications Air Cooled Welding Gun For GMAW And FCAW Welding Note Using gasless flux cored wire reduces gun duty cycle M 25 Feeds 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires Duty Cycle Rating 100 250 A With CO Shielding Gas 150 A With Mixed Gases 60 300 A With CO
14. ee wire feeder manual for threading procedure 804 465 A OM 227 796 Page 4 SECTION 4 OPERATION 4 1 Operating The Gun 1 Trigger Switch S nergized wire feeds and shielding gas flows OM 227 796 Page 5 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing A Turn off welding power source wire feeder Nozzle Contact Tip Tip Adapter A OO N Head Nozzle Adapter Tube Wire size stamped on tip check and match wire size 7 16 in disconnect gun 5 8 in from feeder Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out straight before gun casing A e installing new liner Reassemble gun in reverse order from taking it apart Install 3 4 in 20 mm acu Liner Onn Stickout Thread wire according to welding power source wire feeder manual Tools Needed COP C Xie 3 5 8 7 16 in 804 466 A OM 227 796 Page 6 5 2 Replacing Switch And Or Head Tube Wer A Turn Off welding power source wire feeder and disconnect gun 1 Remove handle locking nut 4 Secure head tube in vice 3 Slide handle
15. liable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard 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 specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 2005 04 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS FOR GMAW WELDING GUNS READ BEFORE USING ES Usages eet vase e BASS EEE T Ate bas wR ANA 1 2 GMAW Gun Hazards t dre eroe P aa Rey IA 1 3 California Proposition 65 Warnings 2 EMF INFORMATION xepexa e xr rx EF EE AUA PPS IEEE REY SECTION 2 SAFETY INFORMATION ul IIR ri x uer exi a eee eee ei ete ie let SECTION 3 INSTAELATION 003 wx EUR IDEE xg He erue Re E imei Acer 317 Specifications ae e les cet a buche gual oe apetece a ede
16. muffs if noise level manufacturers instructions for material used is high Warn others nearby about noise hazard WELDING WIRE can cause puncture wounds 1 Keep hands and body away from gun tip when trigger is pressed OM 227 796 Page 1 WELDING can cause fire or explosion 1 Do not weld near flammable material 2 Donot weld on closed containers 3 Watch for fire keep extinguisher nearby BUILD UP OF GAS can injure or kill 1 Shutoff shielding gas supply when not in use 2 Always ventilate confined spaces or use approved air supplied respirator 1 3 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which For Gasoline Engines contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm A Battery posts terminals and related accessories contain lead For Diesel Engines and lead compounds chemicals known to the State of A Diesel engine exhaust and some of its constituents are known California to cause cancer and birth defects or other to the State of California to cause cancer birth defects and reproductive harm Wash hands after handling other reproductive harm N OTE P Considerations About Welding And The Effects Of Low Frequenc
17. n daa al ee E RR e e e ns 3 2 Duty Cycle And Overheating amuanann 323 2 installing GUID XL sts xor o Ren ERN RE EUREN NGA Rx Ee e e e enun Pf SECTION 4 OPERATION sr scensi Decetric ee ev is 4 1 Operating The GUI ise eis Aaa A A A As SECTION 5 MAINTENANCE amp TROUBLESHOOTING euu 5 1 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing 5 2 Replacing Switch And Or Head Tube 5 3 Routine Maintenance AA eel See gah eect I ake WAA 5 4 Troubleshooting eoe noe AA eee Ce a ea ae A Re SECTION 6 PARTS LIST soriana saone nada bree Seb Cae eee Oe ee ee WARRANTY SECTION 1 SAFETY PRECAUTIONS FOR GMAW WELDING GUNS READ BEFORE USING SR7_8 03 1 1 Symbol Usage Means Warning Watch Out There are possible hazards with this A Marks a special safety message procedure The possible hazards are shown in the adjoining symbols I Means NOTE not safety related e 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 1 2 GMAW Gun Hazards 4 WARNING GMAW WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS
18. y Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of To reduce magnetic fields in the workplace use the following the U S Congress Office of Technology Assessment Biological procedures Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very large 2 volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly 4 5 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around the body establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet About Pacemakers allow us to draw definite conclusions about questions of possible risk The above procedures are among those also normally or to offer clear science based advice on strategies to minimize or recommended for pacemaker wearers Consult your doctor for avoid potential risks complete information Keep welding power source and cables as far away as practical Connect work clamp to workpi
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