Miller GL-25 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
September
1977
FORM:
OM-1515
/
liETU~~~
Copy
~
~
Effective
With
Style
No.
HH-1
MODEL
GL-25
GL-40
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNER.S
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
ADDITIONAL
COPY
PRICE
20
CENTS
NWSA
CODE
NO.
4579
~&.a~
L~P
LLP
~
~
S.
I
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
I.
Arc
welders,
power
sources,
and
components
. . .
I
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
~j
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
I
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
(lays
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
I
year
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
.
.
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
normal
useful
life
of
less
than
one
(I)
year,
such
as
spot
welder
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
~
p
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
therefor
shall
be,
at
Millers
optIon,
(1)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
actual
use)
upon
return
of the
goods
at
Customers
risk
and
CX~
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR
(
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
~b
~
...~i,
~
~
~
~
~
~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
flLE
COPY
RETUG~N
10
~LDE~
Item
Part
No.
Listed
No.
in
Parts
List
28
052084
28
052085
BE
SURE
TO
PROVIDE
Replaced
With
Part
No.
Description
Quantity
081
580
LINER,
monocoil
0.230
OD
x
.030
-
1/8
wire
x
lift
or
1
081
581
LINER,
moriocoil
0.230
OD
x
.030
-
1/8
wire
x
16
ft
1
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1515
Page
A
1
~I~I
r~~
SECTION
1
-
INTRODUCTION
Rating:
60%
Duty
Cycle
Wire
Diameter
Cooling
Method
Cable
Length
Net
Weight
Ship
Weight
250
Amperes
1/16
and
5/64
A
ir
icr
7lbs.4oz.
(3.29
kilos)
9lbs.4oz.
(4.20
kilos)
15
9lbs.Boz.
(4.31
kilos)
11
lbs.8oz.
)5.22
kilos)
400
Amperes
i/16,5/64,
and
3/32
Air
10
9
lbs.
(4.08
kilos)
ii
lbs.
)5.00
kilos)
15
11
lbs.
(4.99
kilos)
13
lbs.
)5.90
kilos)
Figure
1-1.
Specifications
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment,
All
informa
__________________
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises,
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
___________
This
gun
is
designed
specifically
for
use
with
the
self-shielding
Flux-Cored
Arc
)FCAW)
Welding
process
using
self-shielding
flux-cored
electrode.
The
gun
may
be
used
for either
DC
straight
or
DC
reverse
polarity
applications.
All
necessary
components
for
the
specific
wire
size
ordered
are
shipped
with
the
gun.
The
Contact
tube
is
the
only
component
that
needs
to
be
changed
when
a
wire
size
change
is
desired.
_____________
SECTION
2
-
INSTALLATION
2-1.
INSTALLATION
OF
MONOCOIL
LINER
1.
Lay
gun
cable
out
straight.
2.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly
against
wire
straightener
(in
head
tube
behind
contact
tube;
see
Parts
List
for
view).
3.
Tighten
set
screw
in
head
tube
(via
clearance
hole
on
top
of
handle)
and
in
cable
Connector.
Do
not
overtighten.
4.
If
the
monocoil
liner
protrudes
from
the
cable
connector
)feeder
end),
cut
the
liner
off
flush
with
the
end
of
the
cable
connector.
2-2.
INSTALLATION
OF
GUN
TRIGGER
SWITCH
PLUG
1.
Make
connections
from
the
gun
trigger
switch
cord
to
the
plug
for
the
control/feeder
as
follows:
A.
MM
plug:
Attach
the
two
wires
to
the
two
terminals
on
the
plug;
tighten
screws;
slide
insulator
onto
plug.
B.
LN-7
and
LN-8:
Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
the
two
wires
to
pins
A
and
Con
the
five-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT.
and
NOTE
blocks
found
throughout
this
manual:
1L~Il.J~IIuIIJ
I
Under
this
heading,
installation,
ope
rating,
and
main-
1
tenance
procedures
or
practices
will
be
found
that
ii
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
r~TA~1
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
NOTE
1
I
I
I
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
nhtain
the
most
efficient
operation
of
the
equipment
ci
C.
LN-22:
Slide
the
cable
clamp
(strain
relief)
Onto
the
cord;
solder
the
two
wires
to
pins
A
and
C
on
the
three-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
D.
AA
2900:
Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
the
two
wires
to
pins
A
and
D
on
the
four-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
2.
When
the
connections
have
been
properly
made,
the
plug
is
ready
to
be
attached
to
the
control/feeder
gun
switch
receptacle.
I
Prior
to
installing
the
gun,
ensure
that
the
control/
feeder
and
welding
power
source
are
both
completely
disconnected
from
their
respective
input
electrical
power
supplies.
1
I
2-3.
GUN
TO
CONTROL/FEEDER
CONNECTIONS
1.
Slide
one
end
of
the
interconnecting
power
cable
onto
the
threads
on
end
of
cable
connector,
where
applicable.
OM-1515
Page
1
2.
Rotate
outlet
guide
onto
cable
connector;
tighten
outlet
guide.
3.
Loosen
the
outlet
guide
securing
screw
on
the
drive
assembly
of
the
control/feeder.
4.
Insert
the
outlet
guide
from
the
gun
cable
all
the
way
into
the
outlet
guide
hole
on
the
drive
assembly
of
the
control/feeder.
5.
Tighten
the
outlet
guide
securing
screw.
6.
Connect
the
plug
installed
in
Section
2-2
to
the
gun
switch
receptacle
on
the
control/feeder.
7.
Connect
the
remaining
end
of
the
interconnecting
power
cable
to
the
weld
cable
terminal
on
the
control/feeder,
where
applicable.
2-4.
CHANGING
WIRE
SIZE
The
contact
tube
in
the
gun
is
the
only
component
in
the
gun
and
gun
cable
assembly
that
needs
to
be
changed
to
accommodate
a
different
wire
size.
The
contact
tube
is
threaded.
To
remove,
rotate
in
a
counterclockwise
direction;
to
install,
rotate
in
a
clockwise
direction.
2-5.
NOZZLE
A
nozzle
(1-3/4)
is
recommended
for
normal
applications.
If
longer
stick
out
of
the
electrode
is
desired,
a
longer
nozzle
(2-3/8)
is
available
but
must
be
ordered
(see
Parts
List).
Should
very
close
work
be
done
where
the
nozzle
is
not
desired,
a
thread
protector
is
available
for
use
when
the
nozzle
is
removed
(see
Parts
List).
SECTION
3
-
MAINTENANCE
a.
Lay
cable
out
straight.
b.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly
against
wire
straightener
(in
head
tube
behind
contact
tube;
see
Parts
List
for
view).
c.
Tighten
set
screw
in
head
tube
and
in
cable
connector.
Do
not
overtighten.
d.
If
a
new
monocoil
liner
has
been
installed,
cut
the
liner
off
flush
with
the
feeder
end
of
the
cable
connector.
e.
Reinstall
the
interconnecting
power
cable,
where
applicable.
f.
Reinstall
the
outlet
guide.
3-2.
INSPECTION
AND
UPKEEP
Usage
and
conditions
will
determine
the
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice.
3.
Repair
or
replace
cables
as
required;
give
particular
attention
to
frayed
and
cracked
insulation
and
areas
where
the
cables
enter
equipment.
4.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cables.
r
I
S
L!1
Ensure
that
the
welding
power
source
is
completely
shut
down
and
that
power
is
removed
from
the
control/feeder
prior
to
performing
any
maintenance
procedures.
3-1.
CLEANING
MONOCOIL
LINER
Periodically,
depending
on
usage
and
conditions,
it
will
be
necessary
to
clean
the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
To
clean,
proceed
as
follov~s:
-
1.
Remove
monocoil
liner
as
follows;
a.
Remove
outlet
guide
from
cable
connector.
b.
Remove
interconnecting
power
cable
from
cable
con
nector,
where
applicable.
c.
Remove
set
screw
from
cable
connector
and
from
head
tube
(via
clearance
hole
on
sop
of
handle).
d.
Lay
cable
out
straight,
and
pull
monocoil
liner
out
from
feeder
end.
2.
Blow
monocoil
liner
out
with
clean,
dry,
compressed
air.
3.
Blow
casing
out
in
same
manner.
4.
Reinstall
monocoil
liner
as
follows;
Page
2
September
1977
FORM:
OM-1515
Effective
With
Style
No.
HH-1
MODEL
GL-25
GL-40
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
31
Figure
A
Complete
Assembly
TC-052
230
p
10
1
2 3
4
5
67
30
13
23
24
29
28
OM-1515
Page
1
Quantity
Item
Factory
Model
No.
Part
No.
Description
GL-25
GL-40
Figure
A
Complete
Assembly
1
601
957
SCREW,
cap
-
steel
hex
hd
1/4-20
x
1-1/2
1
1
2
052
066
HANDLE,
gun
-
left
hand
1
1
3
076
762
PIN,
spring
-
compression
2
2
4
000
369
SWITCH,
limit
10
amp
125/250
volts
ac
SPDT
1
1
5
052064
TRJGGER,gun
1
1
6
052
884
SCREW,
set
-
steel
socket
hd
10-32
x
1/4
1
1
7
052
072
TUBE,
head
(8
inch)
1
1
8
052
074
INSERT,
straightener
-
wire
1
1
9
052 098
SCREW,
set
-
steel
hollow
3/8-16
x
3/16
1
1
10
052
059
PROTECTOR,
thread
or
1
1
10
052
078
NOZZLE,
screw
1-3/4
or
1
1
10
052
075
NOZZLE,
screw
2-3/8
1
1
11
009709
TUBE,contact
1/l6wireor
1
1
11
052
055
TUBE,
contact
5/64
wire
or
1
1
11
008
926
TUBE,
contact
3/32
wire
1
12
052060
SHIELD,hand
1
1
13
052
095
SCREW,
set
-
steel
socket
hd
5/16-18
x
1/2
1
1
14
601
856
NUT,
weld
5/16-18
1
1
15
602
207
WASHER,
lock
-
steel
split
1/4
1
1
16
601
865
NUT,
steel
-
hex
full
1/4-20
2
2
17
052068
HANDLE,gun-right
hand
1
1
18
052088
CABLE/CONDUIT.
lOft
or
1
18
052089
CABLE/CONDUIT,
l5ft
1
18
052 090
CABLE/CONDUIT,
10
ft
or
1
18
052091
CABLE/CONDUIT,l5ft
1
19
053
076
CLAMP,
hose
1
inch
clamp
dia
1
1
20
005
177
STRAIN
RELIEF
1
1
052
083
TUBING,
neoprene
5/8
ID
x
3/32
waIl
x
6
1
21
052
063
CONNECTOR,
cable
-
gun
1
1
22
052
883
SCREW,
set
-
steel
socket
hd
10-32
x
3/8
1
1
23
052
092
CABLE,
connecting
-
power
(MM-30
Series
only)
1 1
24
052
058
GUIDE,
wire
-
outlet
1/16
-
3/32
(MM-30
Series)
or
1
1
24
052056
ADAPTER,gun/feeder
1/16-3/32
(2900)
or
1
1
24
052 057
ADAPTER,
gun/feeder
1/16
-
5/64
(LN-22)
or
1
1
24
052
158
ADAPTER,
gun/feeder
1/16
-
3/32
(LN-8)
1 1
25
604
523
CAP,
twist
lock
-
midget
2P2W
1
1
25
073
329
PLUG,
4
pin
97-3106A-18-4P
(2900)
1
1
073
331
CLAMP,
cable
(2900)
1
1
25
052236
PLUG,3pinMS-3106A-14S-1P(LN-22)
1
1
039
828
STRAIN
RELIEF,
receptacle/plug
(LN-22)
1
1
25
052237
PLUG,5
pin
MS-3106A-18-11P
(LN-8)
1
1
073
332
CLAMP,
cable
(LN-8)
1
1
26
052086
CORD,trigger
11
ftor
1
1
26
052
087
CORD,
trigger
16
ft
1
1
27
053132
STRAIN
RELIEF,cable
1
1
28
052084
LINER,monocoil
1/16-3/32wirex
11
ftor
1
1
28
052085
LINER,monocoil
1/16-3/32wirex
16ft
1
1
29
052
071
CLAMP,
head
tube
1
1
30
057
544
SPRING,
compression
1 1
31
052
919
SCREW,
machine
-
steel
round
hd
1/4-20
x
7/8
1
1
Parts
For
Optional
Equipment
7
052
419
TUBE,
head
(12
inches)
28
052
837
LINER,
monocoil
1/1
6-3/32
wire
x
16
ft.
4
inches
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1515
Page
2
-~-Th
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
Miller GL-25 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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