Miller KA25 Owner's manual

KA25
Miller
Brand
Miller
Model
KA25
Category
Welding System
Type
Owner's manual

This manual is also suitable for

The Miller KA25 is a heavy-duty, air-cooled welding gun designed for professional use in Gas Metal Arc Welding (GMAW) processes. With a 100% duty cycle and a wide range of compatible wire sizes (0.045 to 1/8 inches or 1.1 to 3.2 millimeters), this gun is suitable for various welding applications. It features a lightweight design with a 10 or 15-foot cable for easy maneuverability. The Miller KA25 is a reliable and versatile choice for industrial welding tasks, ensuring precise and efficient welding performance.

The Miller KA25 is a heavy-duty, air-cooled welding gun designed for professional use in Gas Metal Arc Welding (GMAW) processes. With a 100% duty cycle and a wide range of compatible wire sizes (0.045 to 1/8 inches or 1.1 to 3.2 millimeters), this gun is suitable for various welding applications. It features a lightweight design with a 10 or 15-foot cable for easy maneuverability. The Miller KA25 is a reliable and versatile choice for industrial welding tasks, ensuring precise and efficient welding performance.

Millerfi
August
1990
FORM:
OM-1520B
El
fe
ctlve
WI
th
Style
No
.
KA-25
MODEL:
GA-50P
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.,
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
A-139
588
PRINTED
IN
U.S.A
ir
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
ThIs
limIted
warranty
supersedes
all
previous
MILLER
warranties
ar-id
is
exclusive
with
no
other
guarantees
or
warr5nties
expressed
or
Implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below.
MILLER
Electric
Accessory
Kits
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
*
Replacement
Parts
MILLER
equipment
sold
alter
the
effective
date
of
this
limited
warranty
is
Iree
of
de
tects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
MILLERS
True
BlueSM
Limited
Warranty
shall
not
apply
to:
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT-
-
NESS.
I
Items
furnished
by
MILLER.
but
manufactured
by
others,
such
as
engInes
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
Within
the
warranty
periods
listed
below.
MILLER
wilt
repair
or
replace
any
war-
any.
ranted
parts
or
components
that
fall
due
to
such
defects
in
material
or
workmanship,
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
and
relays.
followed.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER.
or
equip-
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
went
that
has
been
improperly
installed,
improperly
operated
or
misused
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
start
on
the
date
that
Ihe
equipment
was
delivered
to
the
original
retail
purchaser,
and
necessary
maintenance,
or
equipment
which
has
been
used
for
Operation
and
are
as
follows:
outside
of
the
specifications
for
the
equipment.
1.
5
Years
Parts
-3
Years
Labor
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
*
Original
main
power
rectifiers
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
2.
3
Years
Parts
and
Labor
In
Ihe
event
Of
a
warranty
claim
covered
by
this
warranty.
the
exclusIve
remedies
*
Transformer/Rectifier
Power
Sources
shall
be,
at
MILLERS
Option:
(1)
repair:
or
(2)
replacement;
Or,
where
authorIzed
In
Plasma
Arc
Cutting
Power
Sources
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repairor
replace-
Semi-Automatic
and
AutoMatic
Wire
Feeders
mentatanauthorizedMlLLERservicestation.or(4)
paymentoforcredltforthepur.
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
Robots
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
3.
2
Years
Parts
and
Labor
wilIbeF.O
B.,FactoryatAppleton,Wisconsin.orF.O.B
alaMlLLERauthorizedser
vice
facility
as
determined
by
MILLER.
Therefore
no
Compensation
or
reImburse-
Engine
Driven
Welding
Generators
menl
for
transportation
costs
of
any
kind
will
be
allowed.
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.(
TO
THE
EXTENT
PERMITTED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
4,
1
YearParts
and
Labor
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
*
Motor
Driven
Guns
LIABLE
FOR
DIRECT.
INDIRECT,
SPECIAL.
INCIDENTAL
OR
CONSEQUENTIAL
Process
Controllers
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY
*
Water
Coolant
Systems
HF
Units
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
GrIds
PANTY.
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
Spot
Welders
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
*
Load
Banks
THEORY
WHICH.
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
*
SDX
Transformers
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
*
Running
Gear/Trailers
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
*
Field
Options
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
rM
(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
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
one
year
whichever
is
grealer)
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
spa
5.
6
Months
Batteries
citic
legal
righls.
and
other
rights
may
be
available,
bul
may
vary
lrom
state
to
stale.
6.
90
Days
Parts
and
Labor
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
MIG
Guns/TIG
Torches
waived,
the
limitations
and
exclusions
set
Out
above
may
not
apply.
This
Limited
*
Plasma
Culling
Torches
Warranty
provides
specific
legal
rights,
and
other
righls
may
be
available,
but
may
Remote
Controls
vary
Irom
province
to
province
.1
~r~
,
OM-1520B
-
8/90
RECEIVING-HANDLING
Before
unpacking
equipment,
checkcartonforanydam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_______________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1
General
Information
And
Safety
1
1-2
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
SPECIFICATIONS
2-1.
Duty
Cycle
1
2-2.
Description
1
SECTION
3
INSTALLATION
3-1.
Gun/Feeder
Adapter
Connection
2
3-2.
Gun
Switch
Connection
2
3-3.
Shielding
Gas
Connection
2
SECTION
4-
SEQUENCE
OF
OPERATION
4-1.
Gas
Metal
Arc
Welding
(GMAW)
3
4-2.
Shutting
Down
3
SECTION
5
MAINTENANCE
5-1.
Inspection
And
Upkeep
4
5-2.
Contact
Tube
Replacement
4
5-3.
Cleaning
The
Monocoil
Liner
And
Casing
4
5-4.
Changing
Liner
And
Wire
Sizes
5
SECTION
6
PARTS
LIST
Figure
6-1.
Exploded
View
Of
Gun
Assembly
8
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
2-2.
Wire
Sizes
1
Table
5-1.
Wire
Size
And
Parts
Changeover
Data
5
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
forthe
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
onlyby
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source.
1-2
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
4A
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
4A
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2-
SPECIFICATIONS
Table
2-1.
SpecIfications
Ampere
Ratina
100%
Duty
Cycle
(DCEP*)
Wire Diamter
And
Type
Cable
And
Hose
Length
Cooling
Method
Net
Weight
Ship
Weight
500
Amoeres
With
~O2
0.045
through
1/8
in.
(1.1
throuah
3.2
mm)
Hard
And
lIux
Cored
10
ft.
(3.0
m)
Air
13
lbs.
(5.9
kg)
15
lbs.
(6.8
kg)
15
ft.
(4.5
m)
Air
15
lbs.
(6.8
kg)
17
lbs.
(7.6
kg)
*DC
Electrode
Positive
2-1.
DUTY
CYCLE
The
duty
cycle
of
a
welding
gun
is
the
percentage
of
aten
minute
penod
that
a
gun
can
be
operated
at
a
given
out
put.
This
gun
is
rated
at
100%
duty
cycle.
This
means
that
the
gun
can
be
operated
continuously.
2-2.
DESCRIPTION
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal
Arc
V~elding
(GMAW)
process.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered.
Through
minor
changes
in
parts,
the
gun
may
be
used
with
the
wire
sizes
listed
in
Table
2-2.
Table
2-2.
WIre
Sizes
INCHES
MILLIMETERS
0.045
1.1
1/16
1.6
5/64
2.0
3/32
2.4
7/64
2.8
1/8
3.2
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
A
-
Air
Cooled
50
-
Ampere
Rating:
500
Amperes
P
-
Pistol
Grip
(Straight
Head
Tube)
OM-1520
Page
1
SECTION
5-
MAINTENANCE
INSPECTION
AND
UPKEEP
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts,
frayed
or
cracked
cable
insulation;
repair,
tighten,
or
replace
as
required.
2.
Remove
grease,
grime,
and
moisture
from
gun
han
dle
and
cables.
4A
CAUTION:
FLYING
DIRT
AND
METAL
PARTI
CLES
can
Injure
personnel
and
damage
equipment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
3.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air
whenever
changing
wire
or
liner.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
5-2.
CONTACT
TUBE
REPLACEMENT
(Figure
3-1)
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Remove
the
nozzle.
2.
Cut
oft
any
wire
thai
extends
beyond
the
contact
tube.
3.
Remove
the
contact
tube
and
replace
with
the
ap
propn
ate
size
contact
tube.
4.
Reinstall
the
nozzle
and
resume
operation.
OM-1520
Page
4
5-3.
CLEANING
THE
MONOCOIL
LINER
AND
CASING
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Clean
the
monocoil
Iinerand
casing
to
remove
any
metal
chips
and
dirtthat
may
have
accumulated.
Frequency
of
cleaning
is
dependent
on
usage
and
operating
condi
tions.
To
clean,
proceed
as
follows:
1.
Remove
the
nozzle.
2.
Cut
off
any
wire
that
extends
beyond
the
contact
tube.
4A
CAUTION:
LOOSE
WELDING
WIRE
can
cause
Injury.
Keep
a
firm
hold
on
the
wire
during
installa
tion,
removal,
and
threading
operations.
Spooled
wire
has
a
tendency
to
unravel
rapidly
when
loosened
from
the
spool.
3.
Retract
the
remaining
welding
wire
onto
the
wire
spool
and
secure.
4.
Remove
the
contact
tube
(see
Figure
3-1).
5.
Disconnect
the
gun
assembly
from
the
controV
feeder.
6.
Remove
the
outlet
wire
guide
from
the
gun/feeder
connector.
7.
Loosen
the
monocoil
setscrews
on
the
gun
handle
and
the
insulator.
8.
Disconnect
the
gas
hose
from
the
gas
connector.
9.
Loosen
the
body
nut
and
remove
the
head
tube
body.
10.
Remove
the
head
tube.
11.
Pull
out
and
remove
the
monocoil
liner.
a
CAUTION:
FLYING
DIRT
AND
METAL
PARTI
CLES
can
Injure
personnel
and
damage
equipment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
12.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air
to
remove
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
a
a
13.
Lay
the
gun
and
cable
out
flat
and
straight
with
no
17.
Install
and
thread
the
welding
wire
(see
wire
feeder
kinks
or
coils.
Owners
Manual
for
procedure).
14.
Insert
monocoil
liner
fully
into
the
casing.
5-4.
CHANGING
LINER
AND
WIRE
SIZES
(Figure
~
CAUTION:
OVERTIGHTENING
LINER
3.1)
SETSCREWS
can
damage
monocoll
liner.
Do
not
overtighten
liner
setscrews.
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
15.
Tighten
the
liner
setscrews.
wounds;
HOT
SURFACES
can
cause
severe
burns.
16.
Make
gun
connections
as
instructed
in
Section
3.
Do
not
touch
live
electrical
parts.
4A
WARNING:
ELECTRIC
SHOCK
can
kill;
Shut
down
welding
power
source
and
wire
WELDING
WIRE
can
cause
puncture
feeder
before
working
on
gun.
wounds;
ENERGIZED
WELDING
WIRE
may
cause
arcing
when
touching
conductive
ob-
Disconnect
gun
from
wire
feeder
before
in
jects.
specting,
maintaining,
or
servicing.
Do
not
touch
live
electrical
parts.
Allow
a
cooling
period
before
servicing.
Do
not
point
gun
toward
any
part
of
the
body,
other
personnel,
or
any
conductive
surface
when
threading
welding
wire.
Each
time
the
size
of
the
electrode
wire
is
changed,
it
is
necessary
to
change
some
of
the
gun
parts
such
as
the
Use
cold
wire
JOG
button,
if
available,
to
contact
tube,
outlet
wire
guide,
and
liner.
These
thread
wire.
changes
permit
smooth
wire
feeding.
See
the
wire
The
welding
wire
and
all
metal
parts
in
contact
feeder
Owners
Manual
for
instructions
on
installing
the
with
it
are
energized
when
the
gun
switch
in
inlet
wire
guide.
See
Table
5-1
for
the
required
parts
pressed.
changeover
data.
Table
5-1.
Wire
Size
And
Parts
Changeover
Data
From
This
Size
WIre
To
This
Size
0.45
in.
(1.1
mm)
1/16
in.
(1.6
mm)
5/64
in.
(2.0
mm)
3/32
in.
(2.4
mm)
7/64
In.
(2.8
mm)
1/8
In.
(3.2
mm)
.045in.
(1.1
mm)
N/A
1,2,3,
4,7
1,2,3,
4,7
1,2,3,
4,6,7
1,2,3,
4,6,7
1,2,3,
4,6,7
1/16
in.
(1.6
mm)
1,2,3,
4,7
N/A
1,2
1,2,3,
4,6
1,2,3,
4,6,
1,2,3,
4,6
5/64in.
(2.0
mm)
1,2,3,
4,7
1,2
N/A
1,2,3,
4,6
1,2,3,
4,6
1,2,3,
4,6
3/32in.
(2.4mm)
1,2,3,
4,5,7
1,2,3,
4,5
1,2,3,
4,5
N/A
1,2
1,2
7/64
in.
(2.8
mm)
1,2,3,
4,5,7
1,2,3,
4,5
1,2,3,
4,5
1,2
N/A
1,2
1/8in.
(3.2mm)
1,2,3,
4,5,7
1,2,3,
4,5
1,2,3,
4,5
1,2
1,2
N/A
Key:
1
=
Change
Contact
Tube
5
=
Insert
Rear
Centering
Sleeve
2
=
Change
Inlet
Wire
Guide
6
=
Remove
Rear
Centering
Sleeve
3
=
Change
Monocoil
Liner
7=
Change
Head
Tube
4
=
Change
Outlet
Wire
Guide
To
perform
the
necessary
changes,
proceed
as
follows:
CAUTION:
LOOSE
WELDING
WIRE
can
cause
Injury
1.
Remove
the
nozzle
(see
Figure
3-1).
Keep
a
firm
ho/don
the
wire
during
installa
tion,
removal,
and
threading
operations.
2.
Cut
off
any
wire
that
extends
beyond
the
contact
Spooled
wire
has
a
tendency
to
unravel
rapidly
tube.
when
loosened
from
the
spool.
OM-1520
Page
5
3.
Retract
remaining
welding
wire
onto
wire
spool
and
secure.
4.
Remove
contact
tube.
5.
Disconnect
gun
assembly
from
control/feeder.
6.
Remove
outlet
wire
guide
from
gun/feeder
connec
tor.
IMPORTANT:
If
oniy
contact
tube
and
outlet
wire
guide
need
to
be
changed,
proceed
to
Step
22.
7.
Loosen
monocoil
setscrews
on
gun
handle
and
in
sulator.
IMPORTANT:
Monocoil
liners
used
for
.045
in.
(1.1
mm),
1/16
in.
(1.6
mm),
or5/64
in.
(2.0
mm)
wire
should
be
inserted
or
removed
from
gun
handle
end
of
gun
as
sembly
after
head
tube
body
and
head
tube
have
been
removed.
Liners
used
for
3/32
in,
(2.4
mm),
7/64
in.
(2.8
mm),
or
1/8
in.
(3.2mm)
wire
can
be
inserted
or
removed
from
insulator
endof
gun
assembly.
If
3/32
in.,
7/64
in.
or
1/8
in.
wire
is
to
be
used,
proceed
to
Step
11.
8.
Disconnect
gas
hose
from
gas
connector.
9.
Loosen
body
nut,
and
remove
head
tube
body.
10.
Remove
head
tube.
11.
Pull
out
and
remove
monocoil
liner.
a
CAUTION:
FLYING
DIRT
AND
METAL
PARTI
CLES
can
Injure
personnel
and
damage
equipment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
12.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air
whenever
changing
liner
to
remove
any
loose
metal
chips
and
dirt
that
may
have
accu
mulated.
IMPORTANT:
If
rear
centering
sleeve
does
not
require
changing,
proceed
to
Step
17.
13.
Remove
insulator
from
gun/feeder
connector
to
gain
access
to
centering
sleeve
setscrew.
14.
Loosen
centering
sleeve
setscrew.
15.
Add
or
remove
rear
centering
sleeve
as
determined
by
wire
size
to
be
used.
When
adding
rear
centenng
sleeve,
proceed
as
follows:
a.
Insert
centering
sleeve
into
gun/feeder
connec
tor.
b.
Rotate
sleeve
until
notched
portion
lines
up
with
monocoil
setscrew
hole.
c.
Secure
centering
sleeve
setscrew.
16.
Reposition
insulator
over
gun/feeder
connector.
17.
Lay
gun
and
cable
out
flat
and
straight
with
no
kinks
or
coils.
18.
Insert
new
monocoil
liner
fully
into
casing.
4A
CAUTION:
OVERTIGHTENING
LINER
SETSCREWS
can
damage
monocoil
liner.
Do
not
overtighten
ilner
setscrews.
19.
Tighten
liner
setscrews.
20.
Install
appropriate
size
head
tube
and
head
tube
body.
21.
Reconnect
gas
hose
to
gas
connector.
22.
Install
appropriate
size
contact
tube.
IMPORTANT:
The
new
monocoil
liner
will
be
longer
than
necessary.
Cutoff
excess
ilner
flush
with
outlet
wire
guide.
Smooth
rough
edges.
23.
Install
appropriate
outlet
wire
guide.
24.
Make
gun
connections
as
instructed
in
Section
3-1.
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
Do
not
touch
live
electrical
parts.
Do
not
point
gun
toward
any
part
of
the
body,
other
personnel,
or
any
conductive
surface
when
threading
welding
wire.
Use
cold
wire
JOG
button,
if
available,
to
thread
wire.
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
when
the
gun
switch
in
pressed.
25.
Install
and
thread
the
welding
wire
(see
wire
feeder
Owners
Manual
for
procedure).
OM-1520
Page
6
SECTION
6
PARTS
LIST
OM-1520
Page
7
Figure
6-1.
Exploded
View
Of
Gun
Assembly
TD-080
861-A
9
7
8
7
4
3332
3
1
27
26
38
OM-1520
Page
8
Item
Factory
No.
Part
No.
Figure
6-1.
Exploded
View
Of
Gun
Assembly
1
073476
1
073476
2
078
289
3
078852
4
007501
5
602179
6
075671
7
073
779
8
007395
8
007394
9
007550
10
054972
10
057736
10
054545
10
054353
10
054354
10
054355
10
054356
11
008620
11
075
659
11
075
662
11
075
663
11
075
665
11
075
660
12
601941
13
007579
14
049324
15
604311
16
004890
17
602240
18
079018
19
601
954
20
078
287
21
095949
22
076051
23
079021
24
601
865
25
605
789
26
079856
26
134601
27
009627
27
009628
27
114974
27
114973
27
007594
27
007595
28
079852
28
134600
28
079851
29
079858
29
079861
30
004731
31
048825
32
004733
CLAMP,
strap
rbr5
holes
(loft,
models)
10
CLAMP,
strap
rbr5
holes
(15ft.
models)
15
HANDLE,
gun
LH
1
SCREW,
md
hd
1/4-28x
1-1/4
2
WASHER,
fiat
nylon
17/64
ID
x
7/16
OD
x
3/16
..
2
SCREW,
set
sti
skt
hd
1/4-20
x
1/2
1
NUT,
body
1
WASHER,
flat
phenolic
5/8
IDx
1.11
ODx3/16
..
2
TUBE,
hd
.045
wire
1
TUBE,
hd
1/16-1/8
wire
BODY,
hd
tube
1
TUBE,
contact
.045
wire
or
1
TUBE,
contact
.052
wire
1
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
scr
type
1-3/16
x
2-3/8
1
NOZZLE,
scr
type
5/8
orifice
15/16
x
2-3/8
1
NOZZLE,
spot
fIat
2-5/8
Ig
1
NOZZLE,
spot
inside
2-5/8
Ig
1
NOZZLE,
spot
outside
3-1/8
Ig
1
NOZZLE,
15/16
orifice
x
2-3/8
SCREW,
cap
sti
hex
hd
1/4-20
x
1-3/4
1
BRACKET,
mounting
-
guard
handle
1
SCREW,
machine-brs
binding
hd
5-40
x
1/4
....
4
GROMMET,
rbr
1/4
ID
x
3/8
mtg
hole
1
GUARD,
trigger
1
WASHER,
flat
stl
1/4
1
NUT,
stl
hex
jam
1/4-28
2
SCREW,
cap
stl
hex
hd
1/4-20
x
3/4
1
HANDLE,
gun
RH
1
SPRING,
cprsn
1
INSULATOR,
adapter
1
SCREW,
set
stl
skt
hd
3/8-16
x
1/2
1
NUT,
stl
hex
full
1/4-20
1
SCREW,
set
stl
skt
hd
10-24
x
1/4
1
SLEEVE,
centering
monocoil
1
SLEEVE,
centering
monocoil
LINER,
monocoil
.045
wire
x
lOft
1
LINER,
monocoil
.045 wire
x
l5ft
1
LINER,
monocoil
1/16-5/64wirex
lOft
LINER,
monocoil
1/16-5/64wirex
lSft
LINER,
monocoil
3/32-1/8
wire
lOft
LINER,
monocoil
3/32-1/8
wire
15ft
GUIDE,
wire
outlet
.045-5/64
wire
GUIDE,
wire
outlet
.045-5/64
wire
GUIDE,
wire
outlet
3/32-1/8
wire
CABLE,
conduit
loft
(consisting
of)
CABLE,
conduit
lSft.
(consisting
of)
ADAPTER,
hd
tube/pwr
cable
ADAPTER,
gun/feeder
CLAMP,
cable
conduit
10
10
10 10 10
15 15 15 15 15
1
1 1 1 1
2
2
2
2
2
2 2
2
2
2
1
1 1 1 1
1
1
1
1 1
2
2
2 2 2
1
1
1
1 1
1
1
1 1
1
1
1
1
1
1
1
1 1
1 1
1
1
1
1
1
1
1
1
1
1
1 1 1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
2
2
2
2
2
2
OM-1520
Page
9
Description
Quantity
Model
And
15FT
lOFT
1.2
mm
1.6
mm
.047
.063
fl4Sin
1/1~in
2.0mm 2.4mm
2.8
mm
3.2mm
.079 .094
.110
.126
~/R4in
~/32in
7/A4in
1/Riri
1
1
1
1
1
1
1
1
1
1 1
1 1
1
1
1
1
4
4
1
1
1
1
1 1
2 2
1
1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 1
1
1 1
1
1
1
1 1
1
1
1
1
1 1
1
1
1
1
4 4
4
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1 1
1
1 1
1
1
1 1
1
1
1
1
1
1
Item
Factory
No.
Part
No.
Description
Figure
6-1.
Exploded
View
Of
Gun
Assembly
(Continued)
CLAMP,
cable
conduit
HOSE
ASSEMBLY,
gas
lOft
(consisting
of)
HOSE
ASSEMBLY,
gas
1
5ff
(consisting
of)
FITTING,
hose
brs
nut
5/8-18
RH
FITTING,
hose
brs
barbed
nipple
3/l6tbg
FITTING,
hose
brs
ferrule
.42150
HOSE,
No.1
(order
by
It)
CABLE,
trigger
loft
(consisting
of)
CABLE,
trigger
l5ft
(consisting
of)
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
CLAMP,
cable
CABLE,
No.18
2/C
(order
by
ft)
TERMINAL,
ring
tongue
No.
6
stud
SWITCH,
rocker
operated
DPST
8-ISA
(consisting
of)
SCREW,
machine
brs
binding
hd
4-40
x
3/8
FITTING,
hose
brs
barbed
3/l6tbg
x
1/4
NPT.
FITTING,
hose-brs-barbed
nipple
3/1
6tbg
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 1
1 1
1
1
1
1
1
1
1
1 1 1
*
* *
*
*
1-
1
1
1 1
1
1 1
1
1
1
1
1
1 1
1 1 1
2
2
2
2
2 2
1 1
1
1 1
1
*
*
*
* * *
2
2 2
2 2 2
1
1
1
1
1 1
4
4
4
4
4 4
1 1 1
1
1 1
1
1
1
1 1
1
Item
Factory
No.
Part
No
8
007395
8
007394
10
054972
10
054545
10
054353
10
054354
10
054355
10
054356
25
605789
26
079856
27
009 627
27
009628
27
009
624
27
009625
27
007594
27
007595
28
079852
28
079851
Description
TUBE,hd.O45wire
TUBE,
hd
1/16-1/8
wire
TUBE,
contact
.045
wire
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
SCREW,
set
stl
skt
hd
10-24
x
1/4
SLEEVE,
centering-monocoil
LINER,
monocoiI
.045
wire
x
10
ft
LINER,
monocoil
.045
wire
x
15
ft
LINER,
monocoil
1/1
6-5/64
wire
x
10
ft
LINER,
monocoil
1/1
6-5/64
wire
x
15
ft
LINER,
monocoiI
3/32-1/8
wire
x
10
ft
LINER,
monocoil
3/32-1/8
wire
x
15
ft
GUIDE,
wire
outlet
.045-5/64
wire
GUIDE,
wire
outlet
3/32-1/8
wire
Quantity
Model
lOFT
And
15FT
.2
mm
1.6mm
2.0mm
2.4
mm
2.8
mm
3.2
mm
.047
.063
.079
.094
.110
.126
fl45in
1/1~in
~/F,4ir~
~/~.2in
7/R4in
1/gin
x
x
x
x
x
x x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Quantity
Model
And
15FT
1.2mm 1.6mm
2.0mm
2.4mm 2.8mm
3.2mm
.047
.063
.079
.094
.110
.126
.045in
1/16
in.
5/64
in.
3/32
in.
7/64
in.
1/8
in.
33
004732
34
056462
34
056542
35
010606
36
056851
056
108
37
604550
38
079847
38
079846
39
079878
40
079535
41
048834
42
604525
43
079040
44
011
070
45
604723
+079
196
+056
851
*As
Required
OPTIONAL
+These
items
used
when
attaching
a
50
series
feeder
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
The
Following
Parts
Are
Required
To
Change
The
Gun
Fire
from
One
Wire
Size
To
Another.
(Some
Parts
Are
Common
to
More
Than
One
Wire
Size.)
See
Figure
6-1
For
Identification
Of
item
Numbers.
OM-1520
Page
10
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16

Miller KA25 Owner's manual

KA25
Miller
Brand
Miller
Model
KA25
Category
Welding System
Type
Owner's manual
This manual is also suitable for

The Miller KA25 is a heavy-duty, air-cooled welding gun designed for professional use in Gas Metal Arc Welding (GMAW) processes. With a 100% duty cycle and a wide range of compatible wire sizes (0.045 to 1/8 inches or 1.1 to 3.2 millimeters), this gun is suitable for various welding applications. It features a lightweight design with a 10 or 15-foot cable for easy maneuverability. The Miller KA25 is a reliable and versatile choice for industrial welding tasks, ensuring precise and efficient welding performance.

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