Page 1
OM-708 029 805J
April 1999
Processes
Resistance Spot
Welding
Description
MSW-41T, MSW-42T,
And LMSW-52T
Visit our website at
www.MillerWelds.com
Page 2
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
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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.
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.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.
Page 3
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS 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. Principal Safety Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Or Dressing Tips 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Or Cleaning Tongs 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Adjusting Tong And Hand Lever Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Connecting Input Power 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection For 220 Volts Model 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAMS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Page 5
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
spotom _nd_5/97
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 NO TAG. 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 e m b e r s , a n d f l a m e s .
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 t o 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 of f 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-708 Page 1
Page 6
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 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.
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.
FLYING METAL or DIRT can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
1-4. 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.
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic 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
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 t o b e examined.
OM-708 Page 2
Page 7
2-1. Specifications
SECTION 2 – INTRODUCTION
AC Input
Voltage
Model
Voltage
50/60 Hz
1-Phase
MSW-41T 110
MSW-42T 220
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
6 in
(152 mm)
Input Volts
Output Amps
±10%
5500 4500 3600 5500 4500 3600 6750 5800 4850
Work Capacity
Combined
Combined
Thickness
Mild Steel
1/8 in
(3.2 mm)
1/8 in
(3.2 mm)
3/16 in
(4.7 mm)
MSW-41T MSW-42T LMSW-52T
12 in
(305 mm)
110 220 220
(457 mm)
18 in
Rated
Output At
Output At
50% Duty
Cycle*
1.5 kVA
1.5 kVA
2.5 kVA
6 in
(152 mm)
Welder Dimensions Weight
Height Width Length Net Ship
6 in
(152 mm)
6 in
(152 mm)
6 in
(152 mm)
12 in
(305 mm)
4-1/2 in
(114 mm)
4-1/2 in
(114 mm)
4-1/2 in
(114 mm)
18 in
(457 mm)
SECTION 3 – INSTALLATION
13 in
(330 mm)
13 in
(330 mm)
16 in
(406 mm)
6 in
(152 mm)
34 lb
(15.4 kg)
34 lb
(15.4 kg)
42 lb
(19.1 kg)
12 in
(305 mm)
38 lb
(17.2 kg)
38 lb
(17.2 kg)
45 lb
(20.4 kg)
18 in
(457 mm)
3-1. Installing Or Dressing Tips
A. Installing Tips
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 n o t o v ertighten.
1
3
2
OR
3
Ref. ST-800 155-B / Ref. ST-800 154
OM-708 Page 3
Page 8
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-708 Page 4
Page 9
3-2. Installing Or Cleaning Tongs
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, s o 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-708 Page 5
Page 10
3-3. 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. T urn 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 b een 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-708 Page 6
Page 11
3-4. 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
1
2
2 Push-In Slots (Not Shown)
Use slots as template and install
screws at desired locations leaving
1/8 inch stickout.
Push rear slots firmly against screw
heads, and slide box down onto
screws.
3-5. Connecting Input Power
5
4
3
OR
2
Ref. ST-800 156
Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size
input conductors.
1
1
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
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
Size (AWG)
No. 10
No. 12
No. 10
Input Conductor
Fuse/Circuit Breaker
Size In Amperes
30
15
30
Ref. ST-800 156
OM-708 Page 7
Page 12
4-1. Controls
4
SECTION 4 – 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 of f
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 3-3.
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
3
ST-146 013-A
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
Every Use 3 Months 6 Months
Blow Off
Or
Vacuum
Unit
Inspect
Tips
Replace
Unreadable
Labels
OR
During Heavy Service,
Clean Monthly
OM-708 Page 8
Page 13
5-2. Overload Protection For 220 Volts Model
1
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)
2
5-3. 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 5-2).
Low weld output. Dress or replace tips (see Section 3-1).
Check tip threads. Replace tips if necessary (see Section 3-1).
Remove and clean tongs (see Section 3-2).
Clean ends of tongs and tong holders (see Section 3-2).
Check power switch S1 and/or start switch. Replace if necessary.
Longer than normal weld time required. Dress or replace tips (see Section 3-1).
Clean workpieces.
Adjust tong pressure (see Section 3-3).
Ref. ST-800 233 / Ref. ST-800 185-A
Clean ends of tongs and tong holders (see Section 3-2).
Check input line voltage.
Burn through at point of weld. Shorten weld time (see Section 4-1).
Adjust tong pressure (see Section 3-3).
Dress or replace tips (see Section 3-1).
Realign tips (see Section 3-2).
OM-708 Page 9
Page 14
SECTION 6 – ELECTRICAL DIAGRAMS
Figure 6-1. Circuit Diagram For 110 Volts Models
SA-162 466-B
Figure 6-2. Circuit Diagram For 220 Volts Model
OM-222 Page 10
SA-072 065-B
Page 15
Notes
OM-708 Page 11
Page 16
SECTION 7 – PARTS LIST
. Hardware i s common and
not available unless listed.
3
2
1
45
17
11
10
10
9
7
6
5
4
46
8
31
30
32
37
36
29
35
16
15
3
13
12
33
34
28
14
27
18
19
20
21
3
26
25
22
23
17
19
24
44
43
42
41
40
38-Fig 6-2
39
ST-145 048-B
Figure 7-1. Main Assembly
OM-708 Page 12
Page 17
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Model
41T 42T 52T
Figure 7-1. Main Assembly
1 019 643 HANDLE, carrying 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 019 646 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 601 865 NUT, stl hex full fnsh .250-20 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 602 009 SCREW, cap stl sch .250-20 x 1.250 7 7 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 023 660 WIRING HARNESS, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 023 199 LEVER, operating 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 082 090 LEVER, operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 010 714 PIN, spring CS .312 x 1.750 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 712 LINK, tgl connecting 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 010 713 PIN, spring CS .312 x 1.250 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 010 715 BOLT, pressure adjustment 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 601 876 NUT, stl hex jam .437-20 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 010 668 SCREW, cap stl sch .250-20 x 1.500 2 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 017 668 HOLDER, tong top 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 010 709 CLAMP, tong top 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 010 623 BRAID, tong set of four 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 010 716 CLAMP, connecting top tong braid 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 602 008 SCREW, .250-20 x 1.000soc hexhd 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 602 262 HANDLE, wood 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 024 130 BRACKET, mtg handle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 601 778 BOLT, crg stl .250-20 x 4.500 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 601 854 NUT, al hex .375-24 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 095 297 STUD, stl .375-24 x 3.750 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 026 607 GUARD, spatter 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 128 237 SCREW, 10-32 x .500hexwhd slt stl 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 070 017 INSULATION, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 S1 *011 746 SWITCH, control (consisting of) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 291 CONTACT, assembly switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
023 987 CONTACT, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 292 TOGGLE, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
070 035 BASE 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 122 210 SCREW, 10-32 x .625hexwhd slt stl 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 026 759 INSULATOR, plug sec scr 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 010 711 PIN, spring .375-3.00 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 169 122 HOUSING, front 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 NAMEPLATE (order by model and style number) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 602 024 SCREW, drive U 2 x 3/16 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 010 708 RETAINER, clamp tong 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 026 605 INSULATION, bottom clamp 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 181 179 INSULATION, tong 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 602 004 SCREW, cap stl sch .250-20 x .750 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 010 707 CLAMP, bottom tong 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 039 052 CLAMP, threaded connecting tong braid. . . . . . . . . . . . . . . . . .
(included w/Item 5, Fig 6-2) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 345 TRANSFORMER, pwr main (Fig 6-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 350 TRANSFORMER, pwr main (Fig 6-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 354 TRANSFORMER, pwr main (Fig 6-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143 140 LABEL, warning general precautionary 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 600 675 SPLICE, butt 16-14 wire 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 111 630 SCREW, 10-32 x .250hexwhd slt stl 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 019 642 COVER 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 601 847 NUT, stl slflkg hex mscr 10-32 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 115 104 CONNECTOR, clamp cable 1/2 in 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 094 503 CABLE, pwr 10ft 16ga 3/C 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 094 504 CABLE, pwr 10ft 16ga 3/C 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 026 763 TUBING, gl acrylic No. 7 x 2.500 3 3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 128 237 SCREW, 10-32 x .500hexwhd slt stl 2 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-708 Page 13
Page 18
Item
No.
Replace Coils At Factory Or Factory Authorized Service Station.
Part
No.
Description
Quantity
Model
41T 42T 52T
Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38)
095 345 095 350 095 354
1 026 601 INSULATION 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 026 602 INSULATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 312 COIL, pri 115V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 309 COIL, pri 230V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 308 COIL, pri 230V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 157 STUD, stl No. 10-32 x 8.125 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 156 STUD, stl No. 10-32 x 11.125 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 137 943 NUT, core stud 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 +033 123 BAR, sec 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 +033 122 BAR, sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
. Hardware i s common and
not available unless listed.
ST-141 482-A
Figure 7-2. Transformer, Power Main
+Item 37 on Figure 7-1 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-708 Page 14
Page 19
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
115V 230V
Figure 7-3. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 115 104 CONNECTOR, cable clamp .500 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
not available unless listed.
2
1
3
4
12
11
5
6
10
9
8
7
ST-146 012-D
Figure 7-3. 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-708 Page 15
Page 20
Chart 7-1. 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-708 Page 16
Page 21
Notes
Page 22
Notes
Page 23
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Y our distributor also gives
you ...
Service
Y ou 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.
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
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 Supplies
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer .)
3. 1 Year — Parts and Labor
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* 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
* Induction Heating Coils and Blankets
guarantees or warranties expressed or implied.
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
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 contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
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 bas e d u p o n a c tual 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. I N N O 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 7/00
Page 24
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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
Miller Electric Mfg. Co.
An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 US A
International Headquarters–USA
USA Phone: 920-735-4505 Auto-At t ended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
File a claim for loss or damage during
shipment.
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