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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 catalog 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.

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 parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.

From Miller to You

Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

Summary of Contents for Thunderbolt 225

Page 1: ...ce For SMAW Stick Welding Rated Welding Output Amperage Range Maximum Open Circuit Amperes Input at Rated Load Output 60 Hz Single Phase Overall Dimensions Weight Output Voltage 230 V KW 225 A 25 Volt...

Page 2: ...alue 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 agains...

Page 3: ...f earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable 13 Do not touch electrode if you are in contact with the work ground or anot...

Page 4: ...t their doctor before going near arc welding gouging or spot welding operations FLYING PIECES OF METAL or DIRT can injure eyes 1 Wear safety glasses with side shields or face shield 1 4 Principal Safe...

Page 5: ...ace hands where shown to move unit Get help when moving unit 2 Running Gear Mounting Holes 3 Rating Label Locate unit near correct input power 4 Amperage Adjustment Rod 5 Handle 6 Pin Install as shown...

Page 6: ...GND PE Connect First Minimum input and grounding conductor size is 10 AWG Kcmil not to exceed 87 ft 26 m in length Install conductors in conduit or equivalent into a deenergized line disconnect devic...

Page 7: ...Receptacle 6 Power Switch 1 2 6 3 4 5 2 Minutes Welding 8 Minutes Resting 3 2 Duty Cycle Chart And Volt Ampere Curves rduty1 5 95 ST 001 836 A ST 001 844 A Duty Cycle is percentage of 10 minutes that...

Page 8: ...r source and disconnect input power 1 Shunt Block Apply light coating of high tempera ture grease to shaded areas of both shunt blocks Install amperage control handle and locking pin Turn handle to sp...

Page 9: ...freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry properly stored electrodes See User s Guide also Shorten arc leng...

Page 10: ...lief 240 510 ID x 875mtg hole 1 10 088 297 CORD SET 250V 6 50P 12ga 3 c 6ft 1 11 039 778 RECEPTACLE str 2P3W 50A 250V 1 12 005 656 BLADE fan 6 in 4wg 30deg 175 bore CW 1 13 FM 123 468 MOTOR 230V 50 60...

Page 11: ...D x 500 1 14 020 284 WEDGE coil 1 15 010 653 BEARING thr oil imprg 375 ID x 750 OD x 062 1 16 010 929 WASHER flat stl spr 375 1 17 024 869 COLLAR set w screws consisting of 1 18 024 612 COLLAR set 1 1...

Page 12: ...4 95 OPTIONS AND ACCESSORIES No 11A RUNNING GEAR 041 637 A handle and two wheels with solid rubber tires mount easily to the frame of the Thunderbolt 225 providing convenient portability...

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Page 15: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 16: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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