Miller Multimatic 255 Multi-Process Welder

Multimatic 255

Mj509225N - Zz222222R

Pm- 278174 B

Parts Manual

Multimatic 255 1 Page 2 1 7 8 9 10 11 2 3 4 5 6 Main Assembly

Qty Description Multimatic 255 2 Page 1 277329 1 Base No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  Main Assembly  / 229325 4 Foot, Mtg Unit (See following for subassembly information) 2 1 Center Baffle Assembly (See following for subassembly information) 3 1 Front Panel Assembly (See following for subassembly information) 4 1 Rear Panel Assembly (See following for subassembly information) 5 1 Wire Feed Drive Assembly (See following for subassembly information) 6 1 Windtunnel Assembly 7 286024 1 Circuit Card Assy, Control w/IGBT Modules Mp 8 273869 1 Cord Set, 600V T Tng 10ga 3/C 12ft St Jkt 9 278556 1 Lead Assy, Drive Polarity 10 277905 1 Enclosure, Electronics 11 285532 1 Kit, Wrapper w/Labels / 277356 1 Wrapper Assy / 230363 1 Latch, Slide Flush Mtg Hole 1.750 Wide x 1.500 Lg / 278114 1 Label, Parameter/Polarity / 231983 1 Label, Warning General Precautionary (En/Sp) / 283727 2 Label, Warning Falling Equipment (En/Fr/Sp) / 277984 1 Plug Assy, Elect (Gas Valves) / 281222 1 Harness, Wrg Unit Main / 117865 1 Conn, Rect Mini 045 14skt 2row Plug Cable Lkg

Plg15

Rc53

Rc54

Plg9

Millermatic 255 3 Page 1 2 3 4 5 6 7 8 9 10 11 12 13 Center Baffle Assembly 1 277359 1 Baffle, Center Qty Description No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  2 279504 1 Knob, Tensioner 1/2-13 Thread 3 602247 2 Washer, Flat .531 Id x 1.062 Od x 0.95T Stl Pld Ansi .500 4 186437 1 Spring, Cprsn .845 Od x .110 Wire x 1.500 5 231211 1 Washer, Anti-Turn 6 280091 1 Nut, Hub 7 279587 1 Hub, Spool 12 Inch 8 287119 1 Washer, Brake Plastic 9 271415 1 Shaft, Support Spool 10 274304 1 Channel, Support Spool Hub 11 274305 1 Brace, Support Spool Shaft 12 602216 1 Washer, Lock .502 Id x 0.879 Od x .151T Stl Pld Split .500 13 601879 1 Nut, .500-12 .75 Hex .44H Stl Pld

Multimatic 255 4 Page 1 2 3 4 5 6 7 14 8 9 10 11 13 12 20 19 18 17 15 16 Front Panel Assembly

Qty Description Multimatic 255 5 Page 1 282075 1 Panel Assy, Front w/Pems No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  Front Panel Assembly  2 277362 1 Bezel, Front 3 277653 1 Handle, Half 4 278541 1 Cover, Dust Usb w/Tether / 236343 1 Screw, 008-15 x .37 Hexwhd w/Gndrng Stl Pld Slf Tpg 5 277656 1 Membrane, Switch Control 6 276813 1 Circuit Card Assy, Interface Lcd Display

Pc2

Multimatic 255 6 Page 3 1 2 3 4 5 6 7 8 9 10 Rear Panel Assembly 1 277949 1 Panel, Rear Qty Description No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  2 262572 2 Valve, 24 Vdc 1Way 750-14 Thd 2mm Orf 100Psi 3 282261 1 Bushing, Strain Relief .709/.984 Id x 1.375 Mtg Hole 4 277950 1 Bezel, Rear 5 277653 1 Handle, Half 6 182445 1 Nut, Conduit 1.000 Npt Pld 1.688 Od x .200 Thk 7 272186 2 Nut, .750-14 Nps 1.312Hex .413H Nyl 8 250864 2 Hose, Gas 27 In (MIG) 9 285815 1 Kit, Gas Valve Assy 10 278406 1 Label, Gas Valve MIG/TIG

Multimatic 255 7 Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 25 29 Wire Feed Drive Assembly

Qty Description Multimatic 255 8 Page 1 277437 1 Insulator No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  Wire Feed Drive Assembly  2 281378 1 Motor, Wire Drive w/Lead Assemblies 3 277657 1 Housing, Drive (Machined) 4 277795 1 Lever, Pressure Roll (Machined) 5 172075 1 Carrier, Drive Roll w/Components 24 Pitch 6 173619 1 Carrier, Drive Roll w/Components 24 Pitch 10mm Shaft 7 221976 1 Knob, Tension Adjust Assy 8 273112 1 Pin, Clevis .250 Od x 1.751 Lg w/Groove and Cham 9 010224 1 Pin, Spring CS .187 x 1.000 10 282942 1 Screw, 500-13 x .75 Hex Hd-Phl Stl Pld Slf Tpg Ab 11 174610 3 Screw, M 6 - 1.0 x 20 Soc Hd Button Cap Blk 12 602200 1 Washer, Lock .168 Id x 0.293 Od x .040T Stl Pld Split #8 13 173620 3 Bushing, Motor Mtg 14 604538 1 Washer, Flat .344 Id x 0.688 Od x .065T Stl Pld Ansi .312 15 151828 1 Pin, Cotter Hair .042 x .750 16 602009 1 Screw, .250-20 x 1.25 Soc Hd-Hex Gr8 Pln 17 209079 1 Screw M4 x 0.7 x 16 18 604534 1 Screw, .312-18 x 1.25 Hex Hd-Pln Gr5 Pld 19 166072 1 Spacer, Gear 20 192029 3 Washer, Flat .250 Id x 0.437 Od x .015T Stl Pln 21 233030 1 Screw, .250-20 x .25 Hexwhd Machine Stl Pld 22 602216 1 Washer, Lock .502 Id x 0.879 Od x .151T Stl Pld Split .500 23 263411 1 Fitting, Barbed Gas 24 222035 1 Knob, T 1562 Bar w/312-18 Stud 1000 Lg Plstc 25 189285 2 Roll, Drive V Groove .035-.045 Wire 26 221912 1 Guide, Wire Inlet Nylon .023 - .052 27 602247 1 Washer, Flat .531 Id x 1.062 Od x 0.95T Stl Pld Ansi .500 28 230801 1 Spring, Torsion 29 280210 1 Bolt, Hex Head Flange Stl .375-16 x .500 Gr8 Pld Zc

Multimatic 255 9 Page 1 2 3 4 5 6 7 8 15 16 22 10 11 12 17 18 19 20 21 23 13 14 9 Windtunnel Assembly

Qty Description Multimatic 255 10 Page / 278704 1 Assembly, Magnetics Windtunnel No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  Windtunnel Assembly  1 277435 1 Windtunnel, Lh 2 277108 1 Inductor, Input

L1

L2

T1

D1,D2

Rt1

Fm1,Fm2

Ct1

Rt2

11 Page Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V-Knurled rolls for hard shelled cored wires. 5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Ref. S-0026-B/7-91 Wire Diameter Fraction Decimal Metric .023/.025 in. .030 in. .035 in. .045 in. .023/.025 in. .030 in. .035 in. .045 in. 0.6 mm 0.8 mm 0.9 mm 1.2 mm Kit No. 087131 079594 079595 079596 Drive Roll Part No. Type 087130 053695 053700 053697 V-Grooved V-Grooved V-Grooved V-Grooved Inlet 056192 056192 056192 056193 Wire Guide .030/.035 in. .030/.035 in. 0.8/0.9 mm 204579 203526 V-Grooved 056192 Drive Roll And Wire Guide Kits

Qty Description 12 Page / 087131 Drive Roll And Wire Guide Kits No. Item Mkgs. Dia. No. Part *Recommended Spare Parts ~ Optional Hardware is common and not available unless listed. + When ordering a component originally displaying a precautionary label, the label should also be ordered. when ordering parts from your local distributor. To maintain the factory original performance of your equipment, use only Manufacturer's Suggested Replacement Parts. Model and serial number required Item includes other parts. Item is part of a subassembly.  Drive Roll And Wire Guide Kits  V-Grooved / 087130 Drive Roll / 056192 Inlet Wire Guide / 204579 Drive Roll And Wire Guide Kits V-Grooved / 203526 Drive Roll / 079594 Drive Roll And Wire Guide Kits V-Grooved / 053695 Drive Roll / 079595 Drive Roll And Wire Guide Kits V-Grooved / 053700 Drive Roll / 079596 Drive Roll And Wire Guide Kits V-Grooved / 053697 Drive Roll / 056193 Guide, Wire Inlet