Miller LMSW-52T, MSW-41, MSW-41T, MSW-42, MSW-42T Owner's Manual

OM-716 199 981C

February 2005

Processes

Resistance Spot
Welding

Description

MSW-41, MSW-41T, LMSW-52,

And LMSW-52T

Portable Resistance Spotwelders

Visit our website at

www.MillerWelds.com

From Miller to You

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 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.

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Resistance Spot Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers liés au soudage par points 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 4 . . . . . .

2-4. Principales normes de sécurité 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Or Dressing Tips 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Or Cleaning Tongs 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Adjusting Tong And Hand Lever Pressure 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Installing Handle 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Mounting Control Box 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting Input Power (T Models) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Connecting Input Power (Non-T Models) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls (T Models) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Controls (Non-T Models) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Overload Protection For 220 Volts Model 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Troubleshooting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Notes

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

spotom _nd_8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Resistance Spot Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

SPOT WELDING can cause fire.

Sparks can fly off from the weld. The flying sparks,
hot workpiece, and hot equipment can cause fires,
burns, and explosions.

D Protect yourself and others from flying sparks and hot metal.
D Do not spot weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the weld. If this is not

possible, tightly cover them with approved covers.

D Be alert that welding sparks can easily go through small cracks and

openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Do not spot weld on closed containers such as tanks or drums.
D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Do not exceed the equipment rated capacity.
D Use only correct fuses or circuit breakers. Do not oversize or

bypass them.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

D Properly install and ground this equipment according to this manual

and national, state, and local codes.

D Check and be sure that input power cord ground wire is properly

connected to ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet − always
double-check the supply ground before applying power.

D When making input connections, attach the grounding conductor

first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for dam-

age or bare wiring − replace immediately if damaged − bare wiring
can kill. Check ground conductor for continuity.

D Turn off all equipment when not in use.
D For water-cooled equipment, check and repair or replace any leak-

ing hoses or fittings. Do not use any electrical equipment if you are
wet or in a wet area.

D Use only well-maintained equipment. Repair or replace damaged

parts at once.

D Wear a safety harness if working above floor level.
D Keep all panels, covers, and guards securely in place.

FLYING SPARKS can cause injury.

Very often sparks fly off from the joint area.

D Wear approved face shield or safety goggles

with side shields.

D Wear protective garments such as oil-free, flame-resistant leather

gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Synthetic material usually does not provide such protection.

D Protect others in nearby areas by using approved flame-resistant or

noncombustible fire curtains or shields. Have all nearby persons
wear safety glasses with side shields.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and
machine internal circuits are also live when power is
on. Incorrectly installed or improperly grounded
equipment is a hazard.

D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

HOT METAL can cause burns.

Wear gloves or allow cooling period before servicing
tongs or tips.

D Always wear welding-type, insulated gloves

when using this equipment.

D Do not touch workpiece, tips, or tongs with bare hands.
D Allow tongs and tips to cool before touching.

OM-716 Page 1

MOVING PARTS can cause injury.

FUMES can be hazardous.

The tong tips, tongs, and linkages move during
operation.

D Keep away from moving parts.
D Keep away from pinch points.
D Do not put hands between tips.
D Keep all guards and panels securely in place.
D OSHA and/or local codes may require additional guarding to suit

the application.

D Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the weld to remove

fumes.

D In confined spaces, use an approved air-supplied respirator.
D Do not weld on coated metals, such as galvanized, lead, or cad-

mium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, or if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

D Read the Material Safety Data Sheets (MSDSs) and the manufac-

turer’s instructions for metals, coatings, and cleaners.

Coatings, cleaners, paints, and platings can pro­duce fumes when welded. Breathing these fumes
can be hazardous to your health.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install or operate unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can cause injury.

D Use equipment of adequate capacity to lift the

unit.

D Have two people of adequate physical strength

lift portable units.

D Secure unit during transport so it cannot tip or fall.

FLYING METAL or DIRT can injure eyes.

D Wear approved safety glasses with side

shields or wear face shield.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before go-

ing near resistance spot welding operations.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.
D Reduce duty cycle before starting to weld

again.

1-4. California Proposition 65 Warnings

Y 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.)

Y 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.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten­dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.
National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current will cause electromagnetic fields. There has been and
still is some concern about such fields. However, after examining more
than 500 studies spanning 17 years of research, a special blue ribbon

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou­levard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

committee of the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human­health hazard.” However, studies are still going forth and evidence
continues to be examined.

OM-716 Page 2

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.

spot_fre 8/03

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

2-2. Dangers liés au soudage par points

Y Les symboles représentés ci-dessous sont utilisés dans ce

manuel pour attirer l’attention et identifier les dangers possi­bles. Lorsque vous rencontrez un symbole, prenez garde et
suivez les instructions afférentes pour éviter tout risque. Les
instructions en matière de sécurité indiquées ci-dessous ne
constituent qu’un sommaire des instructions de sécurité plus
complètes fournies dans la normes de sécurité énumérées
dans la Section 2-4. Lisez et observez toutes les normes de sé­curité.

Y Seul un personnel qualifié est autorisé à installer, faire fonc-

tionner, entretenir et réparer cet appareil.

Y Pendant le fonctionnement, maintenez à distance toutes les

personnes, notamment les enfants de l’appareil.

LE SOUDAGE PAR POINTS peut
provoquer un incendie.

Des étincelles peuvent être projetées de la soudure.
La projection d’étincelles ainsi que les pièces et
équipements chauds peuvent provoquer des
incendies, des brûlures et des incendies.

D Protégez-vous, ainsi que toute autre personne travaillant sur les

lieux, contre les étincelles et le métal chaud.

D Ne soudez pas par points dans un endroit où des étincelles peuvent

tomber sur des substances inflammables.

D Déplacez toute matière inflammable se trouvant dans un périmètre

de 10 m de la pièce à souder. Si cela est impossible, couvrez-les de
housses approuvées et bien ajustées.

D Des étincelles du soudage peuvent facilement passer dans

d’autres zones en traversant de petites fissures et des ouvertures.

D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours

un extincteur à portée de main.

D Ne soudez pas par points sur un récipient fermé tel un réservoir ou

un bidon.

D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou

vapeurs inflammables (vapeur d’essence, par exemple).

D Avant de souder, retirez toute substance combustible de vos

poches telles qu’un briquet au butane ou des allumettes.

D Une fois le travail achevé, assurez-vous qu’il ne reste aucune trace

d’étincelles incandescentes ni de flammes.

D Ne dépassez pas la puissance permise de l’équipement.
D Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraî­ner des brûlures graves. L’alimentation d’entrée et
les circuits internes de l’appareil sont également

incorrectement installé ou inadéquatement mis à la terre constitue un
danger.

D Ne touchez pas aux pièces électriques sous tension.
D Portez des gants isolants et des vêtements de protection secs et

sans trous.

actifs lorsque le poste est sous tension. Un poste

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y
a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez­vous aux symboles et aux directives ci-dessous afin de connaître les
mesures à prendre pour éviter tout danger.

D Coupez l’alimentation d’entrée avant d’installer l’appareil ou

d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimenta­tion selon la norme OSHA 29 CFR 1910.147(reportez-vous aux
Principales normes de sécurité).

D Installez le poste correctement et mettez-le à la terre

conformément aux consignes de ce manuel et aux normes
nationales, provinciales et locales.

D Assurez-vous que le fil de terre du cordon d’alimentation est

correctement relié à la borne de terre du sectionneur ou que la fiche
du cordon est branchée à une prise correctement mise à la terre −
vous devez toujours vérifier la mise à la terre avant toute mise sous
tension.

D Avant d’effectuer les connexions d’alimentation, vous devez

connecter en premier lieu le fil de terre - contrôlez les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez-les contre les étincelles et les pièces métalliques
chaudes.

D Assurez-vous régulièrement que les câbles d’alimentation et de

masse ne sont pas endommagés ou dénudé par endroit. Rempla­cez-les immédiatement si c’est le cas : un câble dénudé peut
provoquer la mort. Contrôlez la continuité de la mise à la terre.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Dans le cas d’équipements refroidis par eau, contrôlez les

conduites et raccords; remplacez-les s’ils présentent des fuites.
N’utilisez pas d’équipement électrique si vous êtes mouillé ou dans
une zone humide.

D Utilisez uniquement un équipement en bonne condition. Réparez

ou remplacez immédiatement toute pièce endommagée.

D Portez un harnais de sécurité si vous devez travailler au-dessus du

sol.

D Maintenez en place les panneaux, couvercles et protections de

sécurité.

LES ÉTINCELLES VOLANTES
risquent de provoquer des blessures.

Des étincelles peuvent jaillir de la soudure.

D Portez une visière ou des lunettes de sécurité

avec des écrans latéraux approuvées.

D Portez un équipement de protection: gants en cuir résistant au feu,

chemise épaisse, pantanlons sans revers, chaussures de sécurité
et casquette. Les matériaux synthétiques ne garantissent pas une
bonne protection.

D Protégez les autres occupants du local à l’aide d’un rideau ou d’un

écran ignifuge approprié. Assurez-vous que ces personnes portent
des lunettes de sécurité avec protections latérales.

LE MÉTAL CHAUD peut provoquer
des brûlures.

Portez des gants ou laissez refroidir les électrodres
avant de procéder à l’entretien.

D Portez toujours de gants de soudeur lorsque

vous utilisez cet équipement.

D Ne touchez pas les pièces ni les eléctrodes avec les mains.
D Laissez les électrodes refroidir avant de les toucher.

OM-716 Page 3

DES ORGANES MOBILES peuvent
provoquer des blessures.

Pendant le soudage, les bras et électrodes se
déplacent.

D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement.
D Ne placez pas les mains entre les électrodes.
D Maintenez en place les panneaux et protections de sécurité.
D Les applications peuvent nécessiter des protections

supplémentaires d’après les codes de sécurité locales.

D Ne respirez pas les fumées.
D Si vous soudez à l’intérieur, ventilez le local et/ou ayez recours à

une ventilation aspirante installée près de la soudure pour évacuer
les fumées.

D Dans des lieux exigus, utilisez un appareil respiratoire approprié.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement
n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé,
et si nécessaire, en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

D Veuillez lire les consignes de sécurité et les instructions du

fabricant pour les métaux, revêtements et produits de nettoyage.

LES FUMÉES peuvent être
dangereuses.

Lors du soudage, les revêtements, produits de net­toyage, peintures et placages peuvent dégager des
fumées. Leur inhalation peut être dangereuse.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance

Risque D’INCENDIE OU
D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces infllammables.

D Ne pas installer ni faire fonctionner l’appareil à

proximité de substances inflammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut
blesser.

D Utiliser un engin d’une capacité appropriée

pour soulever l’appareil.

D Faites déplacer les équipements portables par

deux personnes dotées d’une force suffisante.

D Durant le transport, immobilisez l’appareil pour éviter qu’il ne

bascule.

DES PIÈCES DE MÉTAL ou DES
SALETÉS peuvent provoquer des
blessures aux yeux.

D Porter des lunettes de sécurité à coques latéra-

les ou un écran facial.

2-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel­ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.

20402.
National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à

distance.

D Les porteurs d’un stimulateur cardiaque doi-

vent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage par
points.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement;

respecter le cycle opératoire nominal.

D Réduire le facteur de marche avant de poursui-

vre le soudage.

Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec­tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence

L’extrait suivant est tiré des conclusions générales du document intitulé

Biological Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington DC : U.S. Government

Printing Office, mai 1989), publié par le Office of Technology Asses­sment du Congrès américain : «... il existe maintenant d’abondantes
données scientifiques compilées à la suite d’expériences sur la cellule
ou d’études sur des animaux et des humains, qui montrent clairement

OM-716 Page 4

que les champs électromagnétiques basse fréquence peuvent avoir
des effets sur l’organisme et même y produire des transformations.
Même s’il s’agit de travaux de très grande qualité, les résultats sont
complexes. Cette démarche scientifique ne nous permet pas d’établir
un tableau d’ensemble cohérent. Pire encore, elle ne nous permet pas
de tirer des conclusions finales concernant les risques éventuels, ni
d’offrir des conseils sur les mesures à prendre pour réduire sinon élimi­ner les risques éventuels». (Traduction libre)

3-1. Specifications

Model

Voltage

Combined

Output At

SECTION 3 − INTRODUCTION

AC Input

Voltage

50/60 Hz

1-Phase

MSW-41T 110

LMSW-52T 220

*Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period.

Model

Tong Length

Input Volts

Output Amps ±10%

Work Capacity

Combined
Thickness

Mild Steel

1/8 in

(3.2 mm)

3/16 in

(4.7 mm)

MSW-41, 41T LMSW-52, 52T

6 in

(152 mm)

5500 4500 3600 6750 5800 4850

Rated
Output At
50% Duty

Cycle*

1.5 kVA

2.5 kVA

12 in

(305 mm)

110 220

(457 mm)

Welder Dimensions Weight

Height Width Length Net Ship

6 in

(152 mm)

6 in

(152 mm)

18 in

4-1/2 in

(114 mm)

4-1/2 in

(114 mm)

6 in

(152 mm)

SECTION 4 − INSTALLATION

4-1. Installing Or Dressing Tips

A. Installing Tips

13 in

(330 mm)

16 in

(406 mm)

(15.4 kg)

(19.1 kg)

12 in

(305 mm)

34 lb

42 lb

38 lb

(17.2 kg)

45 lb

(20.4 kg)

18 in

(457 mm)

Tools Needed:

3/16 in

9/16 in

1 Threaded Tip
2 Tip With Hexhead Screw
3 Tong
Coat threads with supplied heat

sink compound and install tip onto
tong. Do not overtighten.

1

3

2

OR

3

Ref. ST-800 155-B / Ref. ST-800 154

OM-716 Page 5

B. Dressing The Tips

d = <1/8 in (3.2 mm)

diameter

for 1.5 kVA models;

5/32 in (4 mm)

for 2.5 kVA models

1

1 New Tip
2 Used Tip Requiring Dressing
3 Dressing Method − Keep top

diameter same as a new tip.

Tools Needed:

3d d

2

OR

OM-716 Page 6

4-2. Installing Or Cleaning Tongs

Y OSHA and/or local codes may require addi-

tional guarding to suit the application.

5

4

2

7

1

Y Turn off and unplug welder.

. Be sure tong ends are clean

and not corroded before
installing. Clean tongs with fine
steel wool.

Bottom Tong:

1 Bottom Tong
2 Hole In Spatter Guard
3 Bottom Tong Securing Screws

(4)

Loosen the four screws. If needed,
use a rubber mallet to loosen tong.

Slide tong into bottom tong holder

6

3

as far as possible, and position so
that tip is pointing straight up.

Loosely tighten screws.

Top Tong:

4 Top Tong
5 Top Tong Holder/Pivot Casting
6 Top Tong Securing Screws (4)
Loosen the four screws. If needed

for removal, use a rubber mallet to
loosen tong.

Slide tong into pivot casting as far
as necessary, so that tip mates with
bottom tip when tongs are closed.

Loosely tighten screws.
7 Tips
Adjust tong positions to line up cen-

ters of tips as shown. Tighten
screws.

Tools Needed:

3/16 in

9/16 in

Tong Alignment

4

7

1

Front View Side View

Fine
Steel
Wool

4

7

1

ST-800 155-A / Ref. ST-800 154-A

OM-716 Page 7

4-3. Adjusting Tong And Hand Lever Pressure

2

1

3

5

4

6

Tools Needed:

9/16, 11/16 in

Y Turn off and unplug welder.
Y Excessive tong pressure can dam-

age tips. Do not use tongs as a clamp
or vice to hold workpiece together. If
the two pieces of material to be
welded do not make good contact at
the point of the intended weld, clamp
material to provide good contact be­tween surfaces.

. Tong pressure is adjustable, and must

be checked and/or set before operation.
Correct tong pressure is necessary to
create a quality weld and to prevent
damage to tips.
Too much tong pressure causes the
weld nugget to dimple and material to

7

splash out around the nugget area.
If tong pressure is too weak, parts are
loose when the tongs close, severe arc­ing occurs between workpieces, and no
weld can be made.

1 Front Nut
2 Rear Nut
3 Pivot Casting
4 Hand Lever
5 Tongs
To increase tong pressure, loosen front nut.

The farther the front nut is turned out, the
greater the pressure on the tips when the
hand lever is closed. Turn the rear nut up to
the pivot casting to lock the position.

Ref. ST-800 156

To decrease tong pressure, loosen the rear
nut and turn the front nut up to the pivot cast­ing.

6 Machine Screw
The farther down the screw is turned, the far-

ther the hand lever will close. Adjustment of
this screw will determine if the tongs lock on
the material, or just pull up tight. Adjust screw
to allow lever to be raised easily after the
weld has been completed.

7 Hex Nut
To adjust pressure needed to push down

hand lever, turn the hex nuts located on each
side of the pivot casting.

OM-716 Page 8

4-4. Installing Handle

1

2

3

MSW 41 And 41T Models

MSW 52, And 52T Models

2

1

Tools Needed:

7/16, 3/8 in

Y Turn off and unplug welder.

1 Wodden Handle
2 Handle Bolt
3 Brackets (41 And 41T Models Only)

1

2

Ref. ST-802 056-A

Install handle onto the spot welder as shown

above. For 52, and 52T Models, install han-

dle onto either side as desired for either right-

hand or left-hand use.

OM-716 Page 9

4-5. Mounting Control Box

OR

Push-in slots are provided on rear
of box for wall mounting if desired.
The slots will fit over 1/4 inch hex­head screws. To mount box, pro­ceed as follows:

1 Control Box
2 Push-In Slots (Not Shown)
Use slots as template and install

1

2

screws at desired locations leaving
1/8 inch stickout.

Push rear slots firmly against screw
heads, and slide box down onto
screws.

4-6. Connecting Input Power (T Models)

1

5

4

3

OR

2

ST-800 233-A

Operate spot welder from a sepa­rately fused or circuit breaker pro­tected circuit, and use correct size
input conductors.

1 Rating Label (Not Visible As

Shown On Spot Welder)
2 Cord
3 Parallel Plug On 110 Volts AC

Models
4 Tandem Plug On 220 Volts

1

AC Models
Do not cut ground terminal off plug.
5 Grounded Receptacle
Connect plug to matching

grounded receptacle.

Model

1.5 kVA 110 Volt

1.5 kVA 220 Volt

2.5 kVA 220 Volt

OM-716 Page 10

Size (AWG)

No. 10
No. 12
No. 10

Input Conductor

Fuse/Circuit Breaker

Size In Amperes

30
15
30

Ref. ST-800 233-A

4-7. Connecting Input Power (Non-T Models)

Or

12

Y Input power supply wiring

and receptacle must meet

National Electrical Code and

all other code requirements.

Operate spot welder from a sepa­rately fused or circuit breaker pro­tected circuit, and use correct size

3

4

5

input conductors.
1 Rating Label
2 Cord
3 Parallel Plug On 110 Volts AC

Models
4 Tandem Plug On 220 Volts

AC Models
Do not cut ground terminal off plug.
5 Grounded Receptacle
Connect plug to matching

grounded receptacle.

Model

1.5 kVA 110 Volt

2.5 kVA 220 Volt

Input Conductor

Size (AWG)

No. 10
No. 10

Fuse/Circuit Breaker

Size In Amperes

30
30

Ref. ST-800 156

OM-716 Page 11

5-1. Controls (T Models)

4

SECTION 5 − OPERATION

1

2

1 Spot Weld Timer And Pilot

Light
Weld time adjusts from 0 to 5

seconds. The pilot light turns on
when the weld cycle begins and off
when the cycle ends.

2 Hand Lever
Use lever to open and close tongs.

Close the hand lever during the
welding process to compress the
material between the tips. To adjust
tong pressure, see Section 4-3.

3 Start Switch
Move start switch sideways in ei-

ther direction to start weld cycle.
When weld cycle time ends, or the
start switch is released, weld output
stops, and the timer resets for
another weld cycle.

4 Power Switch

5-2. Controls (Non-T Models)

1

3

ST-146 013-B

1 Hand Lever
Use lever to open and close tongs.

Close the hand lever during the
welding process to compress the
material between the tips. To adjust
tong pressure, see Section 4-3.

2 Start Switch
Use switch to turn weld current On

and Off. Move switch sideways in
either direction to start weld current.
Release switch to stop weld cur­rent.

2

OM-716 Page 12

ST-145 104-A

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING

6-1. Routine Maintenance

Y Disconnect power before maintaining.

Every Use 3 Months 6 Months

Blow Off

Or

Vacuum

Unit

Inspect

Tips

6-2. Overload Protection For 220 Volts Model

Replace

Unreadable

Labels

OR

During Heavy Service,

Clean Monthly

Y Turn Off unit and disconnect

input power.

If fuse opens, unit shuts down. To
replace fuse, proceed as follows:

1 Fuse Holder Cover
2 Fuse F1 (See Parts List)

1

2

6-3. Troubleshooting

Trouble Remedy

No weld output. Check line fuses, and replace if necessary.

For 220 V models, check fuse F1, and replace if necessary (see Section 6-2).

Low weld output. Dress or replace tips (see Section 4-1).

Check tip threads. Replace tips if necessary (see Section 4-1).

Ref. ST-800 233-A / Ref. ST-800 185-A

Remove and clean tongs (see Section 4-2).

OM-716 Page 13

Trouble Remedy

Clean ends of tongs and tong holders (see Section 4-2).

Check power switch (T models only) and/or start switch. Replace if necessary.

Longer than normal weld time required. Dress or replace tips (see Section 4-1).

Clean workpieces.

Adjust tong pressure (see Section 4-3).

Clean ends of tongs and tong holders (see Section 4-2).

Check input line voltage.

Burn through at point of weld. Shorten weld time (see Section 5-1).

Adjust tong pressure (see Section 4-3).

Dress or replace tips (see Section 4-1).

Realign tips (see Section 4-2).

OM-716 Page 14

SECTION 7 − ELECTRICAL DIAGRAMS

Figure 7-1. Circuit Diagram For 110 Volts T-Models

SA-162 466-B

Figure 7-2. Circuit Diagram For 220 Volts T-Model

SA-072 065-B

OM-716 Page 15

Figure 7-3. Circuit Diagram For 110 And 220 Volts Non-T Models

SA-162 467-B

OM-716 Page 16

Notes

OM-716 Page 17

. Hardware is common and

not available unless listed.

SECTION 8 − PARTS LIST

Item

No.

1 019 643 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 019 646 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 601 865 NUT, stl hex full fnsh .250-20 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 602 009 SCREW, cap stl sch .250-20 x 1.250 7 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 023 660 WIRING HARNESS, switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 023 199 LEVER, operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 082 090 LEVER, operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-716 Page 18

Dia.

Mkgs.

Part

No.

Figure 8-1. Main Assembly

Description

Figure 8-1. Main Assembly

ST-145 048-D

Quantity

Model

41,41T 52,52T

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

41,41T 52,52T

Model

Figure 8-1. Main Assembly (continued)

6 010 714 PIN, spring CS .312 x 1.750 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 010 712 LINK, tgl connecting 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 713 PIN, spring CS .312 x 1.250 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 010 715 BOLT, pressure adjustment 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 601 876 NUT, stl hex jam .437-20 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 010 668 SCREW, cap stl sch .250-20 x 1.500 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 017 668 HOLDER, tong top 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 010 709 CLAMP, tong top 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 010 623 BRAID, tong set of four 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 010 716 CLAMP, connecting top tong braid 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 602 008 SCREW, .250-20 x 1.000soc hexhd 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 602 262 HANDLE, wood 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 024 130 BRACKET, mtg handle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 601 778 BOLT, crg stl .250-20 x 4.500 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 204 608 NUT, 312−18 .50hex .34h stl pld elastic stop nut 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 213 080 SCREW, 3/8 X 3 soc shoulder 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 026 607 GUARD, spatter 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 070 017 INSULATION, switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 S1 *011 746 SWITCH, control (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

011 291 CONTACT, assembly switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

023 987 CONTACT, switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

011 292 TOGGLE, switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

070 035 BASE 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 122 210 SCREW, 10-32 x .625hexwhd slt stl 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 026 759 INSULATOR, plug sec scr 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 010 711 PIN, spring .375-3.00 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 169 122 HOUSING, front 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 NAMEPLATE (order by model and style number) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 602 024 SCREW, drive U 2 x 3/16 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 010 708 RETAINER, clamp tong 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 026 605 INSULATION, bottom clamp 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 181 179 INSULATION, tong 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 602 004 SCREW, cap stl sch .250-20 x .750 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 010 707 CLAMP, bottom tong 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 039 052 CLAMP, threaded connecting tong braid. . . . . . . . . . . . . . . . . .

(included w/Item 5, Fig 8-2) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 T1 +095 345 TRANSFORMER, pwr main (Fig 8-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 T1 +095 354 TRANSFORMER, pwr main (Fig 8-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143 140 LABEL, warning general precautionary 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 600 675 SPLICE, butt 16-14 wire 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 082 193 SCREW,010−32X .37 hexwhd−slt stl pld slffmg tap−rw 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 019 642 COVER 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 601 847 NUT, stl slflkg hex mscr 10-32 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 134 900 STRAIN RELIEF, cable flexible .270-.480 cable 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 094 503 CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) 1. . . . . . . . . . . . . . . . . . . . . .

44 094 504 CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 026 763 TUBING, gl acrylic No. 7 x 2.500 3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 128 237 SCREW, 10-32 x .500hexwhd slt stl 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 602 205 WASHER, tooth.195idx0.381odx.025t stl pld int #10 a 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 217 299 SCREW, 250−20X .87 soc hd−hex gr8 pln 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.

OM-716 Page 19

Item

No.

Replace Coils At Factory Or Factory Authorized Service Station.

Part

No.

Description

Quantity

Model

41,41T 52,52T

Figure 8-2. Transformer, Power Main (Fig 8-1- Item 38)

095 345 095 354

1 026 601 INSULATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 026 602 INSULATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 095 312 COIL, pri 115V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 095 308 COIL, pri 230V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 010 157 STUD, stl No. 10-32 x 8.125 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 010 156 STUD, stl No. 10-32 x 11.125 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 137 943 NUT, core stud 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +033 123 BAR, sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +033 122 BAR, sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

3

4

5

. Hardware is common and

not available unless listed.

ST-141 482-A

Figure 8-2. Transformer, Power Main

+Item 37 on Figure 8-1 is included when ordering these items as replacement parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.

OM-716 Page 20

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Model

115V 230V

Figure 8-3. Timer, Spot (230V Illustrated)

041 081 041 082

1 NAMEPLATE, (order by model and style numbers) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 S1 124 511 SWITCH, tgl DPST 40A 600VAC 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 W 194 307 CONTACTOR, 40A 3P (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 210 LINK, connecting contactor terminal 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 032 152 CABINET 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 T2 605 856 TRANSFORMER, control 230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 168 308 PANEL, front 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 TD1 605 952 TIMER, delay reset 5sec 120V 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 046 432 HOLDER, fuse 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 F1 *012 653 FUSE, mintr gl .5A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 087 179 CABLE, interconnecting 10ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PLG1 096 822 CABLE, pwr 10ft 16ga 3/c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PLG1 096 481 CABLE, pwr 10ft 16ga 3/c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 134 900 STRAIN RELIEF, cable flexible .270-.480 cable 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1

3

4

12

11

5

6

10

9

8

7

ST-146 012-E

Figure 8-3. Timer, Spot (230V Illustrated)

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.

OM-716 Page 21

Figure 8-4. Spot Welder Tips

3-1/2”

(89 mm)

STANDARD

3-1/2”

(89 mm)

MO OFFSET

6-1/2” (165 mm)

TT-6

9-1/2”

(241 mm)

TT-9

6” (152 mm) 040 197
12” (305 mm) 040 198
18” (457 mm) 040 199

6” (152 mm) 040 200
12” (305 mm) 040 201
18” (457 mm) 040 202

12” (305 mm) 040 203
18” (457 mm) 040 204

12” (305 mm) 040 205
18” (457 mm) 040 206

Standard Flat

040 211 040 212

MO

Offset

040 215

Standard Flat

040 211 040 212

Standard

040 211 040 212

Flat

7-1/2”

(190 mm)

G-7

FF

FH

8” (203 mm) 040 207

8” (203 mm) 040 208

5” (127 mm) 040 209

Standard

040 211 040 212

FF

FH

Flat

040 213

040 214

S-0550

OM-716 Page 22

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.

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
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig
* Maxstar 150
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources and Coolers
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* 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.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

Effective January 1, 2005

(Equipment with a serial number preface of “LF” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets
* 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 1/05

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

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: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05

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.