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.
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
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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.
Mil_Thank 2005−04
Page 3
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING1 . . . . . . . .
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
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.
Marks a special safety message.
Means NOTE; not safety related.
1-2.GMAW Gun Hazards
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS 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.
1. Always wear dry insulating gloves.
2. Insulate yourself from work and ground.
3. Do not touch live electrode or electrical parts.
4. Repair or replace worn, damaged, or cracked
gun or cable insulation.
5. Turn off welding power source before changing
contact tip or gun parts.
6. Keep all covers and handle securely in place.
GMAW WELDING can be hazardous.
ARC RAYS can burn eyes and skin.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin with spatter-resistant
clothing.
HOT SURFACES can burn skin.
1. Allow gun to cool before touching.
2. Do not touch hot metal.
3. Protect hot metal from contact by others.
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
BUILD UP OF GAS can injure or
kill
1. Shut off shielding gas supply when not in
use.
2. Always ventilate confined spaces or use
approved air-supplied respirator.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. 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
Page 6
1-3.California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
EMF INFORMATION
NOTE
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
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
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
To reduce magnetic fields in the workplace, use the following
procedures:
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 the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
OM-227 796 Page 2
Page 7
SECTION 2 − SAFETY INFORMATION
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
12
2
WARNING
ELECTRIC SHOCK can kill.
3
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
5
6
7
WARNING
NOTE
Turn Off switch when using high frequency.
4
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.
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
1Safety Alert Symbol
2Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3Statement Of Hazard And
Result
4Safety Instructions To Avoid
Hazard
5Hazard Symbol (If Available)
6Safety Banner
Read safety blocks for each
symbol shown.
7NOTE
Special instructions for best
operation − not related to safety.
804 466-A
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
60%: 300 A With CO
Weight With 15 ft (4.6 m) Power Cable: 6.0 lb (2.7 kg)
Identified With On Power Cable
Shielding Gas; 150 A With Mixed Gases
2
Shielding Gas; 250 A With Mixed Gases
2
OM-227 796 Page 3
Page 8
3-2.Duty Cycle And Overheating
See Section 3-1. Specifications for amperage rating and duty cycle.
Definition
0
10
Minutes
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
Overheating
.023 To .045 in (0.6 To 1.1 mm)
Hard Or Flux Cored Wires
100% Duty Cycle At 200 Amperes
100% Duty Cycle At 150 Amperes
Using CO
Using Mixed Gases
Continuous Welding
2
0
Minutes
15
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
60% Duty Cycle At 200 Amperes
6 Minutes Welding4 Minutes Resting
Using CO
Using Mixed Gases
2
A or V
OR
Reduce Duty Cycle
sduty1 5/95
3-3.Installing Gun
1
1Gun Securing Knob
2Gun End
4
3
2
Loosen knob. Insert gun end until it
bottoms against drive assembly.
Tighten knob.
3Gun Trigger Plug
Insert into receptacle, and tighten
threaded collar.
4Friction Terminals
Some applications will require
cutting off trigger plug and installing
0.250 female friction terminals onto
end of leads.
See wire feeder manual for
threading procedure.
804 465-A
OM-227 796 Page 4
Page 9
4-1.Operating The Gun
1
SECTION 4 − OPERATION
1Trigger Switch
When pressed, energized wire
feeds and shielding gas flows.
Ref. 800 797-C
OM-227 796 Page 5
Page 10
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1.Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun
Casing
Turn off welding power
source/wire feeder.
1Nozzle
2
3
4
Head
1
Tube
2Contact Tip
3Tip Adapter
4Nozzle Adapter
Wire size stamped on tip −
check and match wire size.
7/16 in
Remove nozzle,
contact tip, and
adapter.
5/8 in
Blow out
gun casing.
3/4 in
(20 mm)
Cut off wire and
disconnect gun
from feeder.
Unscrew and
remove liner.
Lay gun cable out
straight before
installing new liner.
Reassemble gun in
reverse order from
taking it apart.
Install
Liner
Tools Needed:
OM-227 796 Page 6
5/8, 7/16 in
Liner
Stickout
Thread wire according to
welding power source/wire
feeder manual.
804 466-A
Page 11
5-2.Replacing Switch And/Or Head Tube
Turn Off welding power source
/wire feeder and disconnect gun.
1
Remove handle
locking nut.
2
4
Secure head
tube in vice.
3
Slide handle.
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.
6
Install existing shock washer onto new head tube.
Hand-tighten head tube into cable connector.
Tools Needed:
5
Loosen jam nut.
Remove from vice
and turn head tube
out by hand.
7
8
Remove from vice. Reposition handle and install
switch housing. Secure with handle locking nut.
Place head tube in vice and tighten until
nuts are tight.
3/4 in
Ref. 800 795-D
OM-227 796 Page 7
Page 12
5-3.Routine Maintenance
Turn Off welding power source and disconnect gun before maintaining.
Each Spool Of Wire
5-4.Troubleshooting
TroubleRemedy
Wire does not feed; wire is not energized; wire feeds unevenly.
Blow Out
Gun
Casing
Clean
Nozzle
And Check
Contact Tip
3 Months
Replace
Cracked
Parts
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 5-2).
Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 5-1).
Control
Cord
Gas
Hose
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).
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
Page 15
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.
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
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 IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
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
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & 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
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches and Subarc (SAW) Guns
guarantees or warranties expressed or implied.
* Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers
Miller’s 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 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 PROVIDED 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
Page 16
Owner’s Record
Please complete and retain with your personal records.
Model NameSerial/Style Number
Purchase Date(Date which equipment was delivered to original customer.)
Distributor
Address
City
StateZip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
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
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 & 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
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.