Page 1
OM-743 111 734E
October 1999
Processes
Resistance Spot
Welding
Description
PSW-1020MT
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 - 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. Principal Safety Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Installing or Cleaning Tongs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Coolant Connections 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Hanging Bracket Installation (Portable Models Only) (Optional) 4. . . . . . . . . . . . . . . . . . . . . . .
2-5. Connecting Input Power 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Electrical Service Guide 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Adjusting Tong Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Overload Protection 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Tips 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dressing Tips 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
Page 4
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-743 Page 1
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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 META L o r 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-743 Page 2
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2-1. Specifications
SECTION 2 – INSTALLATION
AC Input
Voltage
Voltage
50/60 Hz
1-Phase
220 45
220 45
*Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period.
Input Work Capacity Combined
Input
Amperage
Work Capacity Combined
Thickness Mild Steel
3/16 in
(4.7 mm)
Rated Output
At 50% Duty
Cycle*
10 kVA
10 kVA
Tong Output Amps
Tong
Length
6 in (152 mm) 9500
12 in (305 mm) 7500
18 in (457 mm) 6500
2-2. Installing or Cleaning Tongs
6
3
2
4
1
7
5
Tong Alignment
7
8
5
Front View Side View
8
7
5
Tools Needed:
Output Amps
±10%
Y Turn off welder and discon-
nect input power.
Weight
Net Ship
140 lb 195 lb
(64 kg) (88 kg)
. Be sure tong ends are clean
and not corroded before installing. Clean tongs with fine steel
wool.
Bottom Tong Installation:
1 Spatter Guard
2 Insulating Strip
Check to see that insulating strip is
not cracked.
Y Electric shock hazard and
possible transformer damage from incorrect part. Do
not replace polyester glass
insulating strip with a metal
strip – use only proper parts
from Parts List.
3 Setscrew
Loosen setscrew.
4 Cam Nut
Turn nut counterclockwise to re-
lease pressure on bottom tong.
5 Bottom Tong
Slide tong into bottom tong holder
as far as possible, and position so
that tip is pointing straight up.
Turn cam nut clockwise to secure
tong in holder.
Tighten setscrew to lock cam in
place.
Top Tong Installation:
6 Top Tong Securing Screws
Loosen the four screws.
7 Top Tong
8 Tips
Slide tong into top tong holder as far
as necessary, so that tip mates with
bottom tip when tongs are closed.
Adjust tong positions to line up centers of tips as shown.
Tighten securing screws to lock
tong in place.
Fine
Steel
Wool
3/16 in
9/16 in
Ref. ST-801 528 / ST-801 436 / Ref. ST-800 154-A
OM-743 Page 3
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2-3. Coolant Connections
123
1 Tong Coolant Hose
2 Hose Clamp
3 Barbed Fitting
4 Coolant-In Fitting
5 Coolant-Out Tube
6 Coolant Hoses (Customer
Supplied)
Install hoses as shown.
. This unit is equipped with a
water control pressure switch
to insure proper cooling. If
there i s not enough pressure to
close the switch, the unit will
not weld. For proper operation,
coolant supply must have a
minimum pressure of 30 psi
(207 kPa), a maximum temperature of 86° F (30° C), and a
flow rate of 2.5 to 3 qt/min (2.4
to 2.8 L/min).
Obtain two hoses of desired length
with 5/16 in (7.9 mm) inside
diameter.
Connect hoses as shown, and secure with hose clamps.
5
4
6
Tools Needed:
5/8 in
2-4. Hanging Bracket Installation (Portable Models Only) (Optional)
1 Hanging Bracket
2 Mounting Hardware
Remove and retain hardware from
transformer housing.
3
1
Install bracket to transformer
housing, and secure with existing
hardware as shown.
3 Eye Bolt With Hardware
Ref. ST-801 526 / Ref. ST-800 142
Tools Needed:
OM-743 Page 4
2
9/16 in
Ref. ST-112 810-E
Page 9
2-5. Connecting Input Power
Connect
GND/PE
Conductor First
Have only qualified persons make
this installation.
Remove left side panel of control
box.
1 Line Disconnect Device
GND/
PE
1
6
L2
L1
2
2 Input And Grounding Conduc-
tors
Select size and length using Section 2-6.
3 Power Switch
4 Line Terminals
5 Ground Terminal
Connect conductors as shown to
deenergized line disconnect
device.
Reinstall side panel.
6 Overcurrent Protection
(Fuses Shown)
Select type and size using Section
2-6.
Tools Needed:
3
4
L1
L2
5
GND/
PE
ssb2.4* 1/94 – Ref. ST-113 034-B / ST-113 030-B / Ref. ST-801 529
2-6. Electrical Service Guide
Input Voltage 220
Input Amperes At Rated Output 45
7/16 in
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 80
Min Input Conductor Size In AWG/Kcmil 6
Max Recommended Input Conductor Length In Feet (Meters) 93 (28)
Min Grounding Conductor Size In AWG/Kcmil 10
Reference: 1996 National Electrical Code (NEC)
OM-743 Page 5
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2-7. Adjusting Tong Pressure
. Tong pressure 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 splash out around the
nugget area.
If tong pressure is too weak, parts are loose when the tongs are closed, severe arcing occurs be-
tween workpieces, and no weld can be made.
1 Operating Lever
1
4
2
3
5
2 Weld Actuator Button And
Start Switch
3 Top Nut
4 Bottom Nut
5 Tongs
Tools Needed:
3/4 in
Ref. ST-800 527
Step 1 Step 2
Loosen both nuts and push
tips together.
Step 4 Step 5
Place material to be welded between tong tips,
and press operating lever (see Section 3-1)
to close tongs. Release operating lever.
Begin to tighten top nut. This causes
tips to open. Stop when opening
is a little less than thickness of material
to be welded. Tighten bottom nut.
Step 3
No Weld
Set controls
(see Section 3-1).
Weld
If tong pressure appears correct, place weld actuator
button in the Weld position, and try a sample weld
according to Section 3-1.
Step 6 Step 7
No Weld
Set controls. If tong pressure is
correct, stop here. If further adjustment
is required, go to next step.
OM-743 Page 6
To INCREASE tong pressure, loosen top
nut 1/4 turn. Tighten bottom
nut. Turn Power on, and go to Step 4.
Step 8
To DECREASE tong pressure, loosen
bottom nut 1/4 turn. Tighten top nut.
Turn Power on, and go to Step 4.
Page 11
3-1. Controls
SECTION 3 – OPERATION
1
4
3
5
2
1 Weld Time Control
Select spot weld time from 0 to 9.99
seconds by turning the knobs.
Weld time begins when the Start
switch is pressed.
2 Weld Current Control
Turn clockwise to increase current.
Changing the weld current value
does not affect the duty cycle rating.
The scale is for reference only.
3 Operating Lever
Press operating lever to press Start
Switch and start weld cycle.
4 Power Switch And Pilot Light
5 Weld Actuator Button
Press and turn button left or right 90
degrees to change positions.
Closing the operating lever presses
the Start Switch. This starts weld
time and energizes the contactor,
providing weld current. Weld current may be stopped at any time by
releasing the operating lever, which
opens the Start Switch. When the
Start switch opens, weld current
stops, and the Weld Time control
automatically resets for another
weld cycle.
ST-113 030-B / Ref. ST-801 525
OM-743 Page 7
Page 12
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING
-1. Maintenance
Y Disconnect power before maintaining.
. During heavy service, maintain monthly.
3 Months
Oil unit.
4-2. Overload Protection
Inspect
tips.
Replace damaged
or unreadable
labels.
Y Turn Off unit.
Fuses F1 and F2 protect the control
circuitry.
If either fuse opens, the unit shuts
down. To replace a fuse, proceed
as shown:
1 Fuse Holder Cover
2 Fuse (See Parts List)
OM-743 Page 8
1
2
Ref. ST-113 030 / Ref. ST-800 185-A
Page 13
4-3. Installing Tips
Tools Needed:
1Tip
2 T elescoping Tube
Removal:
Tips have a Morse Taper and a
press fit.
. Use a vice grip pliers to rotate
and loosen tips. Once loose,
1
2
pull tips straight out.
Y Do not move tips from side to
side when removing or telescoping tube will snap off.
Installation:
Coat taper area of tip with pipe
sealant compound. Pull telescoping tube all the way up, but not
out. Use a plastic or leather
hammer to tap tip into seat. Run
water through tong to check for
leaks.
Repeat if necessary.
4-4. Dressing Tips
d = 3/16–1/4 in (4.8–6.4 mm)
diameter
1
ST-801 437
1 New Tip
2 Used Tip Requiring Dressing
3 Dressing Method – Keep top
diameter same as a new tip.
3d d
2
Tools Needed:
OR
OM-743 Page 9
Page 14
4-5. Troubleshooting
Trouble Remedy
No weld output; pilot light Off. Check line fuses, and replace if necessary (see Section 2-5).
Check fuse(s) F1 and/or F2, and replace if necessary (see Section 4-2).
Turn On power switch.
Check for proper coolant supply pressure (see Section 2.3).
Have Factory Authorized Service Station check contactor W.
Low weld output; pilot light On. Dress or replace tips (see Section 4-3 and/or 4.4).
Remove and clean ends of tongs and tong holders (see Section 2-2).
Adjust tong pressure (see Section 2-7).
Longer than normal Weld Time required. Dress or replace tong tips (see Section 4-3 and/or 4.4).
Clean workpieces.
Adjust tong pressure (see Section 2-7).
Check input line voltage.
Burn through at point of weld. Shorten weld time (see Section 3-1).
Adjust tong pressure (see Section 2-7).
Dress or replace tong tips (see Section 4-3 and/or 4.4).
Realign tips (see Section 2-2).
OM-743 Page 10
Page 15
SECTION 5 – ELECTRICAL DIAGRAM
SB-128 144
Figure 5-1. Circuit Diagram
OM-743 Page 11
Page 16
SECTION 6 – PARTS LIST
14
15
16
17
. Hardware i s common and
not available unless listed.
12
17
16
18
23
19
20
21
22
24
8
41
11
12
7
6
45
13
373822
36
35
34
33
22
29
28
30
27
313213
26
25
10
9
8
3
1 2
OM-743 Page 12
40
39
Figure 6-1. Main Assembly
ST-112 610-E
Page 17
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 6-1. Main Assembly
1 019 651 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 PB1 011 749 SWITCH, PB SPST 3A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
027 948 COLLAR, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 660 PIN, spring 1/8 x 1-1/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 026 611 TUBING, 7/8dia x 1-5/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 110 531 BAR, tong brd clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 351 PIN, spring 3/8 x 2 x 2-11/16 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 017 672 LEVER, operating (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 011 750 PUSH BUTTON, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 601 881 NUT, hex jam 1/2-20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 010 726 SCREW, adj pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 010 736 TUBING, 5/8 OD x 12ga x 5/8 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 010 737 BAR, linkage 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 010 738 TUBING, 5/8 OD x 12ga x 1-3/16 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 601 854 NUT, hex 3/8-24 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 110 510 BOLT, eye stem 3/8 x 1-1/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 605 181 NUT, slflkg hex 3/8-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 605 209 SCREW, cap hexhd 3/8-16 x 2-1/4 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 602 213 WASHER, lock split 3/8 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 +110 561 BRACKET, hanging 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109 480 LABEL, warning falling equipment etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 017 671 HOLDER, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 010 723 CLAMP, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 010 744 BAR, ton brd clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 601 117 CLIP, jiffy 1/2 in 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 010 724 BRAID SET, ton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 110 534 SPLATTER BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 110 530 INSULATION, tong bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 110 529 CLAMP, tong bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 110 533 STRIP, insulator polyest gl lam .125 x 2.750 x 3.312 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 112 480 SCREW, set skt hd 1/4-28 x 3/8 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 110 536 CAM, tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 110 903 HOUSING, front transformer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 110 535 CAM, pin tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 010 719 STUD, stl .375-24 x 5.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 602 317 PIN, spring 3/8 x 4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 110 898 PIN, spring 1/4 x 4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 110 532 BAR, tong brd clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 T1 121 317 TRANSFORMER, pwr main (220V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 112 664 CAP, transformer rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
026 295 STRIP, polyest gl lam .062 x 1.687 x 2.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 010 739 SHIELD, tube contact 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 110 901 TUBING, coolant secondary 5/16 OD x .032 x 3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 026 834 TUBING, 5/16 ID x 7/16 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 010 033 STUD, 1/4-28 x 7-3/4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 105 HOSE, nprn brd No. 1 x .312 (order by ft) 7ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111 028 CABLE, pwr 12ft 6 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111 026 CABLE, switch 13ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 610 CONNECTOR, clamp cable 1/2 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 102 CONNECTOR, clamp cable 1 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 323 CLAMP, hose 1/4 x 5/8dia 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quantity
+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 serial number required when ordering parts from your local distributor.
OM-743 Page 13
Page 18
. Hardware i s common and
not available unless listed.
9 10
13
12
14
11
8
7
15
14
16
17
18
19
20
21
22
23
6
3
2526
1 2
4
5
4
28
27
24
ST-113 016-B
Figure 6-2. Control Box
OM-743 Page 14
Page 19
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 6-2. Control Box
1 010 476 BUSHING, strain relief 5/8 ID x .570mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 604 102 CONNECTOR, clamp cable 1 in 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 110 563 CASE SECTION, front/top/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 105 HOSE, nprn brd No. 1 (order by ft) 12ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 323 CLAMP, hose .250-.625clp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 053 525 FITTING, brs barbed M 5/16tbg x 1/8NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 602 965 FITTING, pipe brs tee 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 049 469 HANDLE, carrying 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 602 243 WASHER, flat stl std .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 787 WASHER, lock stl int tooth .500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 910 WASHER, flat stl SAE .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 S3 151 969 SWITCH, pressure oil 4PSI No cont 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Z 110 897 REACTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 +110 542 PANEL, side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 035 049 LINK, connecting contactor term 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 W 034 909 CONTACTOR, 4P 115/230V (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
034 910 COIL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*034 911 KIT, point 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 TD1 088 891 TIMER, digital 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 044 747 HOLDER, fuse crtg 30A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 F1 128 430 FUSE, cartridge 1A 500V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 F2 *012 633 FUSE, mintr gl 1A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 046 432 HOLDER, fuse mintr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 027 628 LENS, light ind red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 PL1 027 629 BULB, incandescent slide base 120V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 027 631 HOUSING, light slide base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 097 926 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 110 562 PANEL, base cabinet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 S2 011 632 SWITCH, rotary 10 position 50A 300V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 S1 128 755 SWITCH, tgl DPST 40A 600VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 143 140 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 070 371 BLANK, snap-in 1-1/8mtg hole 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 T2 036 630 TRANSFORMER, control 100VA 230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quantity
*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 serial number required when ordering parts from your local distributor.
OM-743 Page 15
Page 20
No. 1 Morse Taper No. 2 Morse Taper
040 218
040 219
040 220
041 003
041 004
041 005
TIPS
040 223
040 308
040 224
040 226
040 298
040 225
040 227
040 216
90 deg
90 deg
90 deg
45 deg
45 deg
45 deg
Pointed No. A-2407
Pointed No. A-2508
Offset No. D-2407
Offset No. SE-4270
Offset FA-24210-12 No. 1 Morse Taper
Offset FP-2523-7
AD-54-1 Adapter
OS-351
. Hardware i s common and
not available unless listed.
6 inch
12 inch
18 inch
6 inch
12 inch
18 inch
041 000
041 001
040 294
040 296
90 deg
90 deg
45 deg
45 deg
12 inch
18 inch
6 inch
18 inch
9
67
5
3
2
4
Figure 6-3. Tongs (Optional)
8
1
ST-027 777-A
OM-743 Page 16
Page 21
Quantity
Item
No.
Part
No.
Description
Holder
45 or 90
Deg
No. 1 Morse Taper No. 2 Morse Taper
6” 12” 18” 6” 12” 18”
Figure 6-3. Tongs (Optional)
1 027 778 TONG, 6 in (consisting of) 90 deg 2. . . . . . . . . . . . . . . . . . . . . .
1 027 777 TONG, 12 in (consisting of) 90 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 776 TONG, 18 in (consisting of) 90 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 781 TONG, 12 in (consisting of) 90 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 780 TONG, 18 in (consisting of) 90 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 770 TONG, 6 in (consisting of) 45 deg 2. . . . . . . . . . . . . . . . . . . . . .
1 027 769 TONG, 12 in (consisting of) 45 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 768 TONG, 18 in (consisting of) 45 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 774 TONG, 6 in (consisting of) 45 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 027 772 TONG, 18 in (consisting of) 45 deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 TIPS, (see chart). . . . . . . . . . . . .
3 010 755 TUBE, telescoping 90 deg 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 031 554 TUBE, telescoping 45 deg 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 010 501 TUBE ASSEMBLY, tong (consisting of) 90 deg 1. . . . . . . . . . .
4 010 502 TUBE ASSEMBLY, tong (consisting of) 90 deg 1. . . . . . . . . . . . . . . . . .
4 010 503 TUBE ASSEMBLY, tong (consisting of) 90 deg 1. . . . . . . . . . . . . . . . . . . . . . . .
4 027 757 TUBE ASSEMBLY, tong (consisting of) 90 deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 027 756 TUBE ASSEMBLY, tong (consisting of) 90 deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 027 766 TUBE ASSEMBLY, tong (consisting of) 45 deg 1. . . . . . . . . . .
4 027 765 TUBE ASSEMBLY, tong (consisting of) 45 deg 1. . . . . . . . . . . . . . . . . .
4 027 764 TUBE ASSEMBLY, tong (consisting of) 45 deg 1. . . . . . . . . . . . . . . . . . . . . . . .
4 027 762 TUBE ASSEMBLY, tong (consisting of) 45 deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 027 760 TUBE ASSEMBLY, tong (consisting of) 45 deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 734 HOLDER, tip 90 deg 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 735 HOLDER, tip 90 deg 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 753 HOLDER, tip 45 deg 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 754 HOLDER, tip 45 deg 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 603 090 O-RING, .625 ID x .812 OD All 1 11111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 498 TUBE, connecting 6 in tong All 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 499 TUBE, connecting 12 in tong All 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 500 TUBE, connecting 18 in tong All 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 053 525 FITTING, brs-barbed M. . . . . .
5/16 tbg x 1/8NPT All 2 22222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 010 758 FITTING, pipe-brs skt hd 3/8 NPT All 1 11111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-743 Page 17
Page 22
Notes
OM-743 Page 18
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 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-A t 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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