Miller SSW-2020ATT, SSW-2040ATT Owner's Manual

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Page 1

OM-745 201 170B

March 2003

Processes

Resistance Spot Welding

Descriptio n

SSW-2020ATT, And SSW-2040ATT

Visit our website at

www.MillerWelds.com

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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 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 orindividual 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.

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. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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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. Dimensions And Weight 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Moving The Spot Welder 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Overview Of System Connections 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Installing Or Cleaning Tongs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Coolant Connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Hanging Bracket Installation (Portable Models Only) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Connecting Input Power 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Electrical Service Guide 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Air Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11. Adjusting Tong Pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Overload Protection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Installing Or Dressing Tips 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

spotom _nd_11/99

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 Section1-4. 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- c h e c k c o n n e c t i o n s .

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.

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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 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.

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 ME TAL 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 W1 17.2, 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-745 Page 2

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2-1. Specifications

Input

Work

Rated Output Amperes

Input

Work

Rated Output Amperes

ATT

Voltage

Input

Capacity

Rated Output

Open-

SECTION 2 – INSTALLATION

Voltage

Models

50/60 Hz

Amps

1-Phase

SSW-2020

SSW-2040

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

230 90

460 45

Capacity Combined Thickness

Mild Stee

1/4 in

(6.3 mm)

1/4 in

(6.3 mm)

Rated Output

At Listed

Duty Cycle*

20 kVA

40%

20 kVA

40%

At Listed Tong Length

6 in

(152 mm)

12,500 10,500 9000 3.55

(305 mm)

2-2. Dimensions And Weight

SSW-2020, 2040 185 lb (84 kg)

Open-

12 in

18 in

(457 mm)

Circuit

Voltage

Dimensions

A 49 in (1245 mm) B 37-1/8 in (943 mm) C* D 10-7/8 in (276 mm) E 9-1/2 in (241 mm) F 11/16 in (18 mm) G 19-1/2 in (495 mm) H 20-7/8 in (530 mm)

I 11/16 in (18 mm)

J 1/2 in (13 mm)

Dia. 4 Holes

Weight

Y Bolt unit to floor to keep

it from falling over.

D E

*Dimension depends upon length of tongs.

See Parts List for sizes.

Ref. 802 751

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2-3. Moving The Spot Welder

1 Rating Label Locate unit near correct input

power supply. 2 Skid Place unit on skid and secure with

straps.

2-4. Overview Of System Connections

SSW Models

Coolant

system

Coolant line (see Section 2-6)

Normally 5/8–18 left– hand threaded receptacles

Coolant line

Slip–on hoses tighten with hose clamps

802 752

Spotwelder

Air in

Air filter/regulator assembly

OM-745 Page 4

Pedestal

Air hose 60 – 100 PSI (see Section 2-10)

Input power line (see Section 2-8)

Foot switch

802 792-A

Page 9

2-5. Installing Or Cleaning Tongs

Y OSHA and/or local codes may require addi-

tional guarding to suit the application.

Y Turn off unit and disconnect

input power.

. 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

Tong Alignment

Front View Side View

802 754 / 801 436 / Ref. 800 154-A

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2-6. Coolant Connections

. It is recommended that a coolant which contains

a base of ethylene glycol and deionized water such as low-conductivity coolant solution, Part No. 043 810, be used to protect against freezing to -37 F (-38 C) or boiling to 227 F (108 C). It also contains a compound that resists algae growth.

Y Turn off power and coolant

supply until installation is complete.

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.

5/8 in

Ref. 802 755 / Ref. 802 758

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2-7. Air Connections

1/4 Inch Pipe Thread

5/8 in

1/4 Inch Pipe Thread

See manufacturer’s instructions supplied with filter/regulator (FR) assembly for complete installation and preparation instructions.

Y Turn off power and air supply

until installation is complete.

1 Air Hoses (Customer

Supplied)

Obtain two hoses of correct size, type, and length. Air-In fittings on control boxes have 5/8-18 left-hand threads.

2 Air Filter Connect one hose to air supply and

other end to input fitting on the regulator.

3 Regulator Plug 4 Regulator

5 Pressure Gauge Remove appropriate regulator plug

and install pressure gauge. Set regulator so air pressure is in

the 60 to 100 psi (414 to 689 kPa) range.

6 Air-In Fitting Connect one end of remaining hose

to regulator output fitting, and connect other end to Air-In fitting.

Ref. 802 761-A

2-8. Electrical Service Guide

20 KVA

Single Phase

Input Voltage 230 460 Input Amperes At Rated Output 90 45 Max Recommended Standard Fuse Rating In Amperes

Time-Delay

Normal Operating 3 125 70

Min Input Conductor Size In AWG/Kcmil 6 10

Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 6 10

Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

110 50

(24)

131 (40)

OM-745 Page 7

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2-9. Connecting Input Power

= GND/PE

Y Always connect green or

green/yellow grounding conductor first.

Install conductors into a deenergized line disconnect device.

Make connections to machine first and supply last.

Y Disconnect and lockout/tag-

out input power before connecting input conductors from unit.

Have only qualified persons make this installation.

Remove left side panel. 1 Line Disconnect Device

7 L2

2 Input And Grounding Conduc-

tors

Select size and length using Section 2-8. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Y Make input power connec-

tions to the machine before making connections into a deenergized line disconnect device. I n the line disconnect device, always connect green or green/yellow grounding conductor to supply grounding terminal first, never to a line terminal.

3 Contactor 4 Line Terminals 5 Grounding Conductor 6 Ground Terminal Reinstall side panel. 7 Overcurrent Protection

(Fuses Shown)

Select type and size using Section 2-8.

OM-745 Page 8

4L1

3/8, 1/2 in

Ref. 802 760

Page 13

2-10. Adjusting Tong Pressure

Y Turn off power before mak-

ing adjustments.

1 Top Nut

13/16 in

2 Bottom Nut 3 Top Linkage 4 Bottom Linkage 5 Tongs

. 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 between workpieces, and no weld

can be made.

Step 1 Step 2

Loosen both nuts and

push tong tips together.

Step 4 Step 5

Start

Place material to be welded between

tong tips, and press start switch or re-

mote foot control (see Section 3-1).

Begin to tighten top nut. This causes tong tips to open. Stop when opening is a little less than thickness of material to be welded. Tighten bottom nut.

Step 3

Set controls.

If tong pressure appears correct, place Weld switch in Weld

position and try a sample weld according to Section 3-1.

Air Supply On

Step 6 Step 7

Air Supply

Set controls. If tong pressure is

correct, stop here. If further adjust-

ment is required, go to next step.

Off

To INCREASE tong pressure, loosen top

nut 1/4 turn. Tighten bottom nut, turn air

and Power On, and go to Step 4.

Step 8

To DECREASE tong pressure, loos-

en bottom nut 1/4 turn. Tighten top nut, turn air and Power On, and go

to Step 4.

Ref. 802 762 / Ref. 161 768-B

OM-745 Page 9

Page 14

3-1. Controls

SECTION 3 – OPERATION

Second row of LCDs displays squeeze time set or weld time set.

4321

First row of LCDs displays actual time set.

1 Time Control Squeeze Time (ST) - Use control to set

enough time for tongs to close and apply full pressure to the work before weld amperage starts. Push ST button, then use buttons 3, 2, 1 to select squeeze time from 0 to 9.99 seconds. Squeeze time begins when the Remote Foot Switch or Start Switch is pressed.

Weld Time (WT) - Push WT button, then use buttons 3, 2 , 1 t o select spot weld time from 0 to 9.99 seconds.

Weld time begins at the end of the squeeze time cycle.

2 Weld Switch Use control to check tong pressure and

alignment without weld amperage present at the tongs. When the switch is in the Set Up position, pressing the Remote Foot Switch

OM-745 Page 10

or Start Switch closes the tongs without starting weld amperage. When the switch is in the Weld position, tongs have weld amperage present after the squeeze time has ended.

3 Weld Amperage Control Turn clockwise to increase current. Chang-

ing the weld current value does not affect the duty cycle rating. The scale is for reference only.

4 Power/Pilot Light/Circuit Breaker

Switch

Use switch to turn On power and pilot light. See Section 4-2 for circuit breaker operation.

802 751 / 200 264-A

5 Fuse F1 See Section 4-2. 6 Remote Foot Switch Use remote foot switch to close tongs and

start squeeze time. If switch is released before squeeze time

ends, the tongs open, and the unit resets for another weld cycle.

If switch is held until squeeze time ends and weld time starts, the switch may be released, and the tongs will stay closed until weld time ends.

If workpiece is to be left between tongs after weld time ends, switch must be held for whatever hold time is desired after welding ends.

Page 15

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

4-1. 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 power before

checking fuse.

Fuse F1 and Power/pilot light/circuit breaker switch S1 protect the control circuitry.

If either the fuse or the circuit breaker opens, the unit shuts down. Turn switch On to reset breaker. To replace a fuse, proceed as shown:

1 Fuse Holder Cover 2 Fuse (See Parts List) 3 Power/Pilot Light /Circuit

Breaker Switch

If a fuse continues to open, or the circuit breaker continues to trip, contact Factory Authorized Service Agent.

802 763

OM-745 Page 11

Page 16

4-3. Installing Or Dressing Tips

A. Installing Tips

Y Turn off power before re-

moving tips.

1Tip 2 Telescoping Tube

Removal:

Tips have a Morse Taper and a press fit.

. Use a vice grip pliers to rotate

and loosen tips. Once loose, 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.

B. Dressing Tips

d = 3/16–1/4 in (4.8–6.4 mm)

diameter

ST-801 437

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

diameter same as a new tip.

3d d

OM-745 Page 12

Page 17

4-4. Troubleshooting

Trouble Remedy

No weld output; pilot light Off. Check line fuses, and replace if necessary (see Section 2-9).

Check fuse F1 and/or Power/pilot light/circuit breaker switch S1, and replace if necessary (see Section 4-2).

Turn On Power/pilot light/circuit breaker switch S1.

No weld output, pilot light on. Check for proper coolant supply pressure (see Section 2-6).

Place Weld Switch S3 in the Weld position (see Section 3-1). Have Factory Authorized Service Agent check contactor W.

Low weld output; pilot light On. Dress or replace tips (see Section 4-3).

Remove and clean ends of tongs and tong holders (see Section 2-5). Adjust tong pressure (see Section 2-10).

Longer than normal W eld Time required. Dress or replace tong tips (see Section 4-3).

Clean workpieces. Adjust tong pressure (see Section 2-10). Check input line voltage.

Burn through at point of weld. Shorten weld time (see Section 3-1).

Adjust tong pressure (see Section 2-10). Dress or replace tong tips (see Section 4-3). Realign tips (see Section 2-5).

Tongs close too slowly . Check air pressure at source and at regulator (see Section 2-7).

Have Factory Authorized Service Agent check and replace air valve, if necessary.

OM-745 Page 13

Page 18

SECTION 5 – ELECTRICAL DIAGRAMS

Figure 5-1. Circuit Diagram For Stationary Models

199 202

OM-745 Page 14

200 302-A

Figure 5-2. Circuit Diagram For Foot Control

Page 19

. Hardware is common and

not available unless listed.

SECTION 6 – PARTS LIST

Figure 6-2

Figure 6-4

Figure 6-5

Figure 6-3

802 764

Figure 6-1. Main Assembly

Quantity

Part

No.

Description

Model

SSW-

2020ATT 2040ATT

Figure 6-1. Main Assembly

209 661 FILTER/REGULATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 6-2 RESISTANCE SPOT WELDER, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 6-4 PEDESTAL, air operated 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 6-3 RFSW-10/20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 6-6 TONGS, (Optional) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 105 HOSE, nprn brd No. 1 x .312 ID (order by ft) 7ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 323 CLAMP, hose .250 -.625clp dia 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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-745 Page 15

Page 20

. Hardware is common and

not available unless listed.

OM-745 Page 16

802 774–A

Figure 6-2. Resistance Spot Welder, Air

Page 21

Item

No.

Dia.

Mkgs.

Part

No.

Description

Model SSW-

Figure 6-2. Resistance Spot Welder, Air (Fig 6-1)

1 000 365 RING, rtng ext .390 shaft grv x .042 E 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 110 524 PIN, cylinder air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 198 639 GUARD, spot welder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 199 115 FITTING, pipe brs 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 199 104 CYLINDER, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 601 881 NUT, stl hex jam .500-20 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 010 749 SCREW, .500-20 x 1.562hexhd stl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 748 TUBING, stl .625 OD x 12ga wall x .203 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 010 746 LINKAGE, upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010 736 TUBING, stl .625 OD x 12ga wall x .203 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 010 726 SCREW, adj pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 010 720 PIN, spring CS .375 x 2.750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 010 747 LINKAGE, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 010 738 TUBING, stl .625 OD x 12ga wall x 1.187 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 017 671 HOLDER, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 010 723 CLAMP, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 010 744 BAR, clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 010 724 BRAID SET, tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 601 117 CLIP, jiffy .500 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 110 534 SPLATTER BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 112 480 SCREW, set .250-28 x .375 cup pt sch stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 110 530 INSULATION, tong bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 110 529 CLAMP, tong bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 110 533 STRIP, polyest gl .125 x 2.750 x 3.312 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 110 536 CAM, tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 110 903 HOUSING, front transformer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 110 535 CAM, pin tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 213 081 SCREW, 3/8 x 4-1/2 soc shoulder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 204 608 NUT, 312-18 .50 hex .34 h stl pld elastic stop nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 602 317 PIN, spring .375 x 4.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 110 898 PIN, spring .250 x 4.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 110 531 BAR, tong braid clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 110 532 BAR, tong braid clamping 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 T1 121 319 TRANSFORMER, power main (230V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 T1 121 320 TRANSFORMER, power main (460V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 110 527 CAP, transformer rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 010 739 SHIELD, tube coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 110 901 TUBING, coolant secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 026 834 TUBING, fbr vulc .312 ID x .437 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 010 034 STUD, .250-28 x 11.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 110 539 BRACKET, mtg cylinder air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

2020ATT 2040ATT

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

OM-745 Page 17

Page 22

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 6-3. RFSW-10/20 (Fig 6-1)

1 185 929 PEDAL/HOUSING/BOTTOM PLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 S1 183 629 SWITCH, limit 10A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 200 288 CABLE, control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 605 156 CABLE, port 20ga 5/c ( order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PLG1 079 878 HOUSING PLUG & PINS (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 187 078 COVER, guard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 182 626 SPRING, ext 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

801 931-B

Figure 6-3. RFSW-10/20

OM-745 Page 18

Page 23

Notes

OM-745 Page 19

Page 24

. Hardware is common and

not available unless listed.

OM-745 Page 20

802 765-A

Figure 6-4. Pedestal, Air Operated (SSW Models)

Page 25

Quantity

T T

tem No.

Dia.

Mkgs.

Part

No.

Description

Model

SSW-

Figure 6-4. Pedestal, Air Operated (Fig 6-1)

1 053 525 FITTING, brs barbed M 5/16tbg x 1/8NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 105 HOSE, nprn brd No. 1 x .312 ID (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 323 CLAMP, hose .250-.625dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 602 965 FITTING, pipe brs tee 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 030 170 BUSHING, snap-in nyl .750 ID x 1.000mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 070 371 BLANK, snap-in nyl 1.093 x 1.125mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 057 357 BUSHING, snap-in nyl .937 ID x 1.125mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 AS1 199 109 VALVE, 115 VAC 2way (5)1/4 nptf piping ports (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . .

7 199 115 FTG, pipe brs qcon elbow male 1/4 npt 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 678 FTG, pipe brs elbow st 1/4 NPTL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 602 243 WASHER, flat stl .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 787 WASHER, lock stl intl tooth .500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 910 WASHER, flat stl SAE .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S5 177 123 SWITCH, pressure oil 4psi NO cont 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S1 198 637 CIRCUIT BREAKER/SWITCH 1 amp lighted 120VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 200 264 NAMEPLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 199 247 SOCKET, relay 11 pin scr term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 TD1 198 636 TIMER, digital al 0-9.99 sec 120 VAC 60 Hz cycle timer 1. . . . . . . . . . . . . . . . . . . . . . . . . .

15 S3 196 575 SWITCH, rocker SPST 10A 250VAC on-none-off .250 qc 1. . . . . . . . . . . . . . . . . . . . . . . . . .

16 044 747 HOLDER, fuse crtg 30A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 F1 *128 430 FUSE, crtg 1A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 097 926 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 RC1 048 282 RECEPTACLE w/skts (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 202 219 GUARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 198 635 CABINET, pedestal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +110 551 PANEL, side pedestal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 201 063 LABEL, warning electric shock can kill, install 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 193 776 LABEL, MILLER 6.093 x 2.593 horizontal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 143 140 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Z 199 200 REACTOR, (230V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Z 199 201 REACTOR, (460V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 W1 213 446 INTERLOCK, cntor NO size 3-1/2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 W 034 909 CONTACTOR, 4P 115/230V (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

034 910 COIL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*034 911 KIT, point 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 035 049 LINK, connecting contactor term 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 T2 202 208 TRANSFORMER, control 100VA 230/460V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 S2 011 632 SWITCH, rotary 10 pos 50A 300V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2020AT 2040AT

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

OM-745 Page 21

Page 26

. Hardware is common and

not available unless listed.

027 777-A

OM-745 Page 22

Figure 6-5. Tongs

Page 27

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 6-6. 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. . . . . . . . . . . . . . . . . . . . . . . . .

4 027 758 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 027 761 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 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . .

5/16tbg x 1/8NPT All 2 2 2 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 010 758 FITTING, pipe brs skt hd 3/8NPT All 1 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-745 Page 23

Page 28

Tongs and Tips (Must be ordered separately from spot welders. One pair of tips are supplied with each set of tongs.)

4–1/4 in

(108 mm)

4–1/4 in

(108 mm)

7–1/2 in

90 mm)

(229 mm)

4–1/4 in (108 mm)

9 in

TONGS

6–1/4 in

(159 mm)

6–1/4 in

(159 mm)

STANDA RD 90°

No. 1 Morse Taper No. 2 Morse Taper

STANDA RD 45°

No. 1 Morse Taper No. 2 Morse Taper

TT–6W

No. 2 Morse Taper

TT–9W

No. 2 Morse Taper

SW–12

TONG LENGTH

6 in

(150 mm)

#040 218 #040 219 #040 220

––

– ––

–

––

12 in

(304 mm)

#041 004 #041 005

–

#071 465

18 in

(457 mm)

#041 001

#040 296

#041 838 #040 308

#041 840

TIPS INCLUDED

#040 223 #040 308

#040 851 #040 225

#040 308

No. 1 P ointed

#071 466

Flat Threaded

#071 467

Top

Bottom

Notes for tongs and ti ps:

Tongs and tips shown to the left can be used with all PSW and SSW model spot welders. Recommended max. tong

length is 18 in (457 mm).

Tong throat–height dimension

for standard 90 and 45 tongs is 4–1/4 in length is measured from the

(108 mm). Throat

center of the spot tips to the front water hose connection.

X = tong length.

One set of tips is supplied with each set of tongs.

Tips are made of RWMA Class 2 alloy .

Maximum welding capabilities are obtained with minimum tong length.

MT= Morse Taper.

No. 1 Morse Taper has smaller diameter than No. 2 Morse Taper.

No. 1 MT (Pointed)

#040 223

No. 1 M T ( Off set)

#040 224

No. 2 MT (Pointed)

#040 308

No. 1 M T ( Off set)

#040 851

No. 1 M T ( Off set)

#040 226

No. 1 M T ( Off set)

#040 298

No. 2 M T ( Off set)

#040 225

No. 1 MT (Pointed)

#071 466

Threaded (Flat)

#071 343

Threaded (Flat)

#071 467

QUANTITYTIPS

2 tips

1 tip for top tong

1 tip f or bottom tong

WHERE USED

Standard No. 1 Tongs, 90°

Standard No. 2 Tongs, 90°

TT–6W Tongs TT–9W Tongs

Standard No. 1 Tongs, 45°

Standard No. 1 Tongs, 90°

Standard No. 2 Tongs, 45°

SW–12 Tong

SW–12 Tong (optional)

SW–12 Tong

OM-745 Page 24

No. 1 MT (Flat Swive l Tip)

Matching Pointed Tip

#040 216

Adapter (adapts No. 1 Morse Taper Tip

to No . 2 recep tacle)

#040 227

2 tips

2 adapters

Standard No. 1 Tongs, 90°

Standard No. 2 Tongs, 90°

TT–6W Tongs (top) TT–9W Tongs (top)

Page 29

Page 30

Page 31

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, 2002

(Equipment with a serial number preface of “LC” 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 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 * Water Coolant Systems * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Maxstar 85, 140 * Spot Welders * Load Banks * 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 * 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 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 B o b cat, 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 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 6/02

Page 32

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  2002 Miller Electric Mfg. Co. 5/02

File a claim for loss or damage during shipment.