Miller AUTO ARC PIN WELDER Owner's manual

Miller
Brand
Miller
Model
AUTO ARC PIN WELDER
Category
Welding System
Type
Owner's manual

This manual is also suitable for

July
1988
FORM:
118583
OWN
ERS
MANUAL
Al
IT/VAI5F1____
I~1
1J
I
~
I~I
I
~.
MILLER
ELECTRIC
MFG.
Co.
718
S.
BOUNDS
ST,
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIQNAL
COPY
PRICE
30
CENTS
IMPORTANT
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Serial
No.
JH304844
MODEL
AUTO
ARC
PIN
WELDER
NWSA
CODE
NO.
4679
PRINTED
IN
U.S.A.
ONE
YEAR
LIMITED
WARRANTY
COVERAGE
-
Miller
Electric
Mlg.
Co.
warrants
to
the
buyer
REMEDY
FOR
DEFECTIVE
WELDER
-
Upon
receipt
of
any
who
purchases
this
Auto
Arc
Welder
(Welder)
for
personal,
defective
Welder,
Miller
Electric
will,
at
its
option,
repair
or
c~
family
or
household
purposes
(Consumer)
that
this
Welder
replace
the
defective
Welder
at
its
expense,
refund
or
credit
~
will
be
free
from
defects
in
material
and
workmanship
for
a
the
purchase
price
(less
reasonable
depreciation
based
on
ac
period
of
one
year
from
the
date
of
purchase.
This
warranty
tual
use),
or
reimburse
the
Consumer
for
the
cost
of
repair
or
,~
covers
only
the
original
purchaser
of
this
Welder.
Miller
Electric
replacement
at
an
approved
Miller
Electric
warranty
station,
~
does
not
authorize
any
party,
including
its
authorized
provided
that
the
purchaser
of
that
Welder
has
followed
the
distributors,
to
offer
any
other
warranty
on
behalf
of
Miller
procedure
for
obtaining
warranty
performance
set
forth
below~
Electric.
Upon
expiration
of
the
warranty
period,
Miller
Electric
The
Welder
so
repaired
or
used
as
a
replacement
will
be
ship-
,~
~
shall
have
no
further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of
the
defective
Welder,
with
transporta
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the
continental
United
States
(transportation
charges
on
shipments
to
Alaska
~
THIS
WARRANTY
IS
OFFERED
IN
LIEU
OF
ANY
OTHER
or
Hawaii
will
be
paid
only
to
the
nearest
port
of
export).
~
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE
EXTENT
~
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
ALL
IMPLIED
WARRANTIES,
INCLUDING
BUT
NOT
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
i*~
LIMITED
TO
THE
IMPLIED
WARRANTIES
OF
MERCHAN-
WELDER,
TO
THE
EXTENT
PERMITTED
BY
APPLICABLE
TABILITY
AND
FITNESS
FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE
LIMITED
TO
THE
REMEDY
PROVIDED
BY
THIS
LIMITED
TO
THE
DURATION
OF
THIS
WARRANTY.
WARRANTY:
AND,
TO
THE
EXTENT
ENFORCEABLE
UNDER
APPLICABLE
LAW,
MILLER
ELECTRIC
SHALL
IN
Some
states
do
not
allow
limitations
on
how
long
an
implied
NO
EVENT
BE
LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
OR
SPECIAL
DAMAGES
ARISING
OUT
OF
THE
USE
OF,
OR
~
This
warranty
gives
you
specific
legal
rights,
and
you
may
also
INABILITY
TO
USE,
THE
WELDER,
WHETHER
BASED
ON
have
other
rights
which
vary
from
state
to
state.
BREACH
OF
THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
STRICT
LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
on-
to
components
having
normal
useful
life
of
less
than
one
(1)
year.
such
as
spot
welder
tips,
relay
and
contactor
points,
Some
states
do
not
allow
the
exclusion
or
limitation
of
c
parts
that
come
in
contact
with
the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
not
apply
to
you.
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
-
defect
in
workmanship
or
material.
PROCEDURE
FOR
OBTAINING
WARRANTY
PERFORMANCE
~
Miller
shall
be
required
to
honor
warranty
claims
on
war
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
As
soon
as
any
defect
in
a
Welder
becomes
known,
the
pur
within
the
following
periods
from
the
date
of
delivery
of
Equip-
chaser
of
the
Welder
must,
within
thirty
(30)
days,
notify
an
ment
to
the
original
user:
approved
Warranty
Station
or
Miller
Electric
in
writing
of
the
1.
Arc
welders,
power
sources,
and
components
1
defect.
The
purchaser
must
then,
within
the
one
year
warranty
year
period,
return
the
Welder
to
Miller
Electric
at
the
following
ad-
2.
Original
main
power
rectifiers
3
years
dress:
(labor~
1
year
only)
3.
All
welding
guns,
feeder/guns
and
plasma
torches
90
ClayS
Miller
Electric
Mt
g.
Co.
4.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
718
South
Bounds
Street
P.O.
Box
1079
WHAT
IS
NOT
COVERED
-
This
warranty
does
not
extend
Appleton,
Wisconsin
54912
~A.
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
warranty
repair
by
anyone
except
Miller
Electric.
Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
~4
warranty
only
extends
to
those
purchasing
the
Welder
for
per-
must
be
prepaid.
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users
are
given
a
different
warranty.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY
RULES
FOR
OPERATION
OF
PORTABLE
RESISTANCE
SPOT
WELDING
EQUIPMENT
1-1.
Introduction
1
1-2.
Installation
1
1-3.
Safety
Devices
1
1-4.
Personal
Safety
1
1-5.
Burn
Prevention
1
1-6.
Fumes
1
1-7.
Fire
Prevention
1
1-8.
Protection
Of
Others
1
1-9.
Cords
1
1-10.
Hoses
1
1-11.
Maintenance
1
1-12.
Standards
Index
1
SECTION
2
INTRODUCTION
2-1.
General
Information
And
Safety
2
2-2.
Receiving-Handling
3
2-3.
Description
3
SECTION
3
INSTALLATION
3-1.
Electrode
Installation
3
3-2.
Electrical
Input
Connections
4
SECTION
4
SEQUENCE
OF
OPERATION
4-1.
Operator
Controls
4
4-2.
Pin
Welding
4
4-3.
Clip
Welding
4
4-4.
Shrinking/Expanding
5
4-5.
Shutting
Down
5
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5
5-2.
Troubleshooting
5
SECTION
1
SAFETY
RULES
FOR
OPERATION
OF
PORTABLE
RESISTANCE
SPOT
WELDING
EQUIPMENT
1-1.
INTRODUCTION
The
following
safety
rules
cover
general
safe
practices
which
as
a
minimum
should
be
employed
when
using
resistance
spot
welding
equipment.
Establishment
of
an
attitude
of
safety
consciousness
is
necessary
for
the
protection
of
personnel
and
property.
Do
not
install,
operate,
or
maintain
this
equipment
be
fore
reading
this
manual.
1-2.
INSTALLATION
All
equipment
should
be
installed
by
qualified
personnel
in
conformance
with
local,
state,
and
federal
codes.
1-3.
SAFETY
DEVICES
Safety
devices
such
as
fuses
should
not
be
discon
nected
or
shunted
out.
1-4.
PERSONAL
SAFETY
Before
installation,
inspection,
or
service
of
equipment,
disconnect
input
power
and
employ
lockout/tagging
pro
cedures
to
prevent
accidental
turning
on
of
power.
Always
shut
off
power
when
leaving
equipment
unat
tended.
Disconnect
provisions
must
be
available
nearthe
equip
ment.
1-5.
BURN
PREVENTION
Wear
long-sleeve
shirt
and
cuff-less
trousers
in
addition
to
gloves,
hat,
and
high
top
shoes.
Button
shirt
collar,
pocket
flaps,
and
sleeve
cuffs
to
avoid
entry
of
sparks.
Woolen
clothing
is
preferable
to
cotton
because
it
is
not
so
readily
ignited.
Cotton
clothing
if
used
should
be
chemically
treated
to
reduce
its
combustibility.
Clothing
treated
with
nondurable
flame-retardent
matenals
should
be
retreated
after
each
wetting
or
cleaning.
Wear
safety
goggles
or
glasses
with
side
shields.
Use
a
face
shield
for
severe
exposure
to
flying
sparks.
Avoid
oils
or
greases
on
clothing
which
could
be
ignited
by sparks
and
do
not
use
flammable
hair
preparations.
Do
not
handle
hot
metal
such
as
tong
tips
or
workpiece
without
wearing
gloves.
1-6.
FUMES
Severe
discomfort
or
illness
can
result
from
fumes
and
vapors
produced
by
welding.
Use
adequate
ventilation
as
described
in
ANSI
Z49.1.
Lead-,
cadmium-,
zinc-,
mercury-,
and
beryllium-bear
ing
and
similar
materials
when
welded
may
produce
harmful
concentrations
of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used
for
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
Both
must
be
used
when
beryllium
is
in
volved.
Metals
coated
with
materials
that
emit
toxic
fumes
should
not
be
heated
unless
the
coating
is
removed
from
the
surface,
the
area
is
adequately
ventilated,
or
the
operator
wears
an
air
respirator.
1-7.
FIRE
PREVENTION
Flying
sparks
can
pass
through
cracks,
windows,
doors,
wall
and
floor
openings,
and
along
pipes.
If
combustibles
are
nearby,
do
not
weld.
Move
work
if
practicable
to
an
area
free
of
combustibles.
If
work
can
not
be
moved,
move
combustibles
to
a
safe
location
or
protect
against
ignition
with
suitable
and
snug-fitting
fire
resistant
covers
or
shield.
Walls,
ceilings,
and
floors
near
the
work
area
should
be
fire
resistant
or
protected
by
fire
resistant
covers
or
shields.
Do
not
weld
where
atmosphere
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
Do
not
exceed
the
equipment
rated
capacity.
After
completion
of
work
inspect
area
to
ensure
it
is
free
of
sparks,
glowing
embers,
and
flames.
1-8.
PROTECTION
OF
OTHERS
Workers
or
other
persons
adjacent
to
the
welding
area
should
be
protected
by
noncombustible
or
flame-resis
tant
screens
or
shields
or
should
be
required
to
wear
suitable
eye
protection.
Booths
and
screens
should
per
mit
circulation
of
air
at
floor
level.
1-9.
CORDS
Frequently
inspect
for
wear,
cracks,
and
damage.
Im
mediately
replace
cords
with
excessively
worn
or
dam
age
insulation
to
avoid
possibly
lethal
shock
from
bared
conductors.
Keep
cords
dry,
free
of
oil
and
grease
and
protect
from
hot
metal
and
sparks.
1-10.
HOSES
On
water
cooled
equipment
examine
hoses
and
fittings
regularly
for
leaks
and
loose
connections.
Repair
or
re
place
leaky
hoses
and
fittings.
Do
not
use
tape
to
repair
leaky
hoses.
1-11.
MAINTENANCE
Remove
leaky
orfaulty
equipment
from
service
immedi
ately
for
repair.
Keep
equipment
clean
and
properly
ad
justed.
1-12.
STANDARDS
INDEX
1.
ANSI
Standard
Z49.1
Safety
In
Welding
And
Cut
ting,
obtainable
from
the
American
Welding
Soci
ety,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
118583
Page
1
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Portable
Resistance
Spot
Welding
Equipment.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
WARNING
and
CAUTION
which
identify
differ
ent
levels
of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
A
third
signal
word,
IMPORTANT
highlights
instn.ic
tions
which
need
special
emphasis
to
obtain
the
most
ef
ficient
operation
of
this
equipment.
2-2.
RECEIVING-HANDLING
Before
installing
this
equipment,
clean
all
packing
mate
rial
from
around
the
unit,
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claim
for
loss
or
damage
that
may
have
occurred
in
tran
sit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manu
facturer
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
2-3.
DESCRIPTION
This
unit
is
a
hand-held
resistance
welding
unit
de
signed
for
use
in
auto
body
repair.
The
unit
can
be
used
for
pin
welding,
welding
trim
moulding
clips,
and
shrink
ing/expanding.
Welding
time
is
determined
by
the
op
erator.
The
unit
is
protected
by
a
circuit
breaker
which
opens
when
an
overload
condition
exists.
Equipment
supplied
includes:
Pin
Welder,
pin
elec
trode,
clip
electrode,
shrinking
electrode,
pins,
clips,
slide
hammer,
and
tool
box
for
storage
of
equipment.
3-1.
ELECTRODE
INSTALLATION
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
HOT
SURFACES
can
burn
skin.
Do
not
touch
live
electrical
parts.
Disconnect
input
powercord
from
po
wersup
ply
receptacle
before
installing
electrode.
Allow
electrode
to
coo/before
touching.
2.
Pull
electrode
from
electrode
holder
assembly,
if
necessary.
3.
Push
desired
electrode
into
electrode
holder
as
sembly.
These
electrodes
are
tapered
and
need
not
be
twisted
or
keyed.
SECTION
3-INSTALLATION
Electrode
Pln
Electrode
Illustrated
Start
Switch
Outer
Electrode
Circuit
Breaker
115
VAC
Power
Cord
And
Plug
FIgure
3-1.
ResIstance
Welder
Components
1.
Select
electrode
according
to
application.
TB-118
775
118583
Page
3
3-2.
ELECTRICAL
INPUT
CONNECTIONS
dards
and
any
additional
state
and
local
codes.
A
cord
with
plug
attached
is
provided
on
this
unit.
Check
nameplate
for
input
voltage
requirement,
and
connect
the
plug
to
a
properly
grounded
and
protected
(fuses
or
circuit
breakers)
115
volt
ac
receptacle
capable
of
sup
plying
15
amperes.
Be
sure
that
the
building
supply
and
receptacle
comply
with
National
Electrical
Code
stan-
IMPORTANT:
The
supply
wiring
for
the
resistance
welder
must
be
capable
of
handling
a
15
ampere
load.
The
resistance
welder
must
be
the
only
load
connected
to
the
supply
circuit.
Poorunit
performance
or
frequently
opening
line
fuses
or
circuit
breakers
can
result
from
an
inadequate
or
improper
supply.
SECTION
4
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Keep
all
covers
in
place
while
operating.
Warranty
is
void
if
resistance
welder
is
operated
with
any
portion
of
the
outer
enclosure
removed.
HOT
METAL
AND
SPARKS
can
cause
fire
and
burns.
Wear
correct
eye,
ear,
and
body
protection.
Allow
equipment
and
work
to
cool
before
han
dling.
Watch
for
fire.
Have
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
FUMES
AND
GASES
can
seriously
harm
your
health.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
apparatus.
MOVING
PARTS
can
cause
serious
Injury.
Keep
clear
of
pinch
points.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operatIon.
Wearers
should
consult
with
their
doctor
be
fore
going
near
welding
operations.
See
Section
1
Safety
Rules
For
Operation
Of
Portable
Resistance
Spot
Welders
for
basic
welding
safety
information.
4-1.
OPERATOR
CONTROLS
A.
Start
Switch
(FIgure
3-1)
The
Start
switch
is
a
spring-loaded,
momentary-contact
push
button
which
provides
on/off
control
of
the
weld
output.
Push
in
and
hold
switch
for
desired
weld
time.
Releasing
the
switch
shuts
off
weld
output.
B.
Circuit
Breaker
The
circuit
breaker
provides
overload
protection.
When
the
unit
is
operated
at
a
rate
that
exceeds
its
capacity,
the
circuit
breaker
opens,
shutting
off
weld
output.
Allow
a
brief
cooling
period
before
resetting
the
circuit
break-
er.
4-2.
PIN
WELDING
Pins
are
welded
onto
auto
body
sheet
metal
dents.
The
supplied
slide
hammer
is
used
to
pull
on
the
pin,
thereby
pulling
out
the
dent
in
the
auto
body
sheet
metal.
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of
entire
Section
4
before
proceedIng.
1.
Install
pin
electrode
(see
Section
3-1).
2.
Insert
pin
into
electrode.
3.
Plug
in
unit.
4.
Be
sure
that
surface
where
pin
is
to
be
welded
is
clean,
bare
metal.
Push
resistance
welder
against
surface
until
electrode
outer
ring
is
seated
against
clean,
bare
metal.
5.
Press
Start
switch
for
0.5
to
1.0
seconds.
There
should
be
no
more
than
1/8
to
1/4
in.
(3.1
to
6.3
mm)
discoloration
around
weld.
6.
Slip
slide
hammer
over
pin
and
tighten.
7.
To
remove
dents,
pull
slide
hammer
with
a
constant
force
and
tap
damaged
area
with
body
hammer.
If
necessary,
use
force
on
slide
hammer
to
pull
dent
out.
8.
Afterdentispulledout,cutoff
pin
and
grind
off
head.
IMPORTANT:
For
larger
indents,
several
pins
can
be
welded
onto
the
body
at
1/2
in.
(13
mm)
interials
and
clamped
together.
Clamped
pins
can
be
pulled
using
a
come-along
or
body
and
frame
straightening
equip
ment.
4-3.
CLIP
WELDING
Trim
moulding
clips
can
be
welded
onto
auto
body
sheet
metal
using
the
resistance
welder.
a
WARNING:
Read
and
follow
safety
informa
tlon
at
beginning
of
entire
Section
4
before
proceedIng.
1.
Install
clip
electrode
(see
Section
3-1).
2.
Insert
clip
into
electrode.
3.
Plug
in
unit.
118583
Page
4
4.
Be
sure
that
surface
where
clip
is
to
be
welded
is
clean,
bare
metal.
Push
resistance
welder
against
surface
until
electrode
outer
ring
is
seated
against
clean,
bare
metal.
5.
Press
Start
switch
for
0.5
to
1.0
seconds.
There
should
be
no
more
than
1/8 to
1/4
in.
(3.1
to
6.3
mm)
discoloration
around
weld.
4-4.
SHRINKING/EXPANDING
High
spots
and
small
dents
can
be
smoothed
by
using
the
shrink
electrode
to
apply
heat
to
these
areas.
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of
entire
Section
4
before
proceedIng.
1.
Install
shrinking
electrode
(see
Section
3-1),
and
plug
in
unit.
2.
Be
sure
that
surface
to
be
worked
on
is
clean,
bare
metal.
Push
resistance
welder
against
surface
until
electrode
outer
ring
is
seated
against
clean,
bare
metal.
3.
Press
Start
switch
for
0.5
seconds
two
or
three
times
to
heat
metal.
4.
If
a
high
spot
does
not
shrink,
tap
lightly
with
body
hammer.
If
a
dent
does
not
expand,
carefuIIy~apply
a
damp
cloth
to
the
heated
metal.
4-5.
SHUTTING
DOWN
Disconnect
input
power
cord
from
receptacle.
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
Al!
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
pre
cautionary
labels.
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
cord
from
power
sup
ply
receptacle
before
inspecting,
maintaining,
or
servicing.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Troubleshooting
of
internal
parts
to
be
per
formed
only
by
qualified
persons.
A.
Power
Cord
Every
three
months
inspect
cord
for
breaks
in
insulation.
Repair
or
replace
cord
if
insulation
breaks
are
present.
Clean
grease
and
moisture
from
cord
at
each
inspec
tion.
B.
Electrode
MaIntenance
Keep
electrodes
clean
and
free
of
grease
and
moisture.
Fine
steel
wool
can
be
used
to
keep
electrode
parts
clean.
A
fine
metal
file
can
be
used
to
keep
the
outer
electrode
flat.
5-2.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
cord
from
power
sup
ply
receptacle
before
inspecting,
maintaining,
or
servicing.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
MOVING
PARTS
can
cause
serIous
Injury.
Keep
clear
of
pinch
points.
Troubleshooting
of
internal
parts
to
be
per
formed
only
by
qualified
persons.
It
is
assumed
that
the
unit
was
properly
installed
accord
ing
to
Section
3
of this
manual,
the
operator
is
familiar
with
the
function
of
controls,
the
resistance
welder
was
working
properly,
and
that
the
trouble
is
not
related
to
the
process.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
resistance
welder.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
contact
the
nearest
Factory
Authorized
Ser
vice
Station.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
fol
lowed.
118583
Page
5
TROUBLE
PROBABLE
CAUSE
REMEDY
No
weld
output.
Open
line
fuse
or
circuit
breaker.
Replace
line
fuse
or
reset
line
circuit
breaker.
Circuit
breaker.
Reset
circuit
breaker.
Weld
circuit
not
complete.
Press
outer
electrode
firmly
against
clean,
bare
metal.
Start
switch.
Replace
Start
switch.
Longer
than
normal
weld
time.
Electrode.
Clean
or
replace
electrode.
Material
to
be
welded
dirty.
Clean
material
to
be
welded.
Burn
through
at
point
of
weld.
Weld
time
too
long.
Shorten
weld
time.
Electrode.
Use
correct,
clean
electrode.
118583
Page
6
July
1988
FORM:
118583
PARTS
LIST
Effective
With
Serial
No.
JH304844
10
11
6
8
2
9
2
28
27~
18~~
TC-116
992
Figure
A
-
Complete
Assembly
Item
Part
No.
No.
Description
Quantity
1
118206
2
118200
3
118199
4
601
865
5
602207
6
118188
7
117921
8
118189
9
+118
186
10
602241
11
601927
12
118190
13
118205
14
601
862
15
+118
187
16
117083
17
117902
18
118193
19
118192
20
118201
21
602020
22
118191
23
118194
24
118198
25
118246
26
118195
27
118196
28
118197
118
247
118
248
117957
117958
117960
117959
042
164
042
165
TRIGGER
BOOT
SCREW,
pan
hd-phillips
6-32
x
3/8
PIN,
electrode
SLIDING,
electrode
SPRING,
return
ELECTRODE
ASSEMBLY,
copper
CLIP
ELECTRODE
SHRINKING
ELECTRODE
SLIDE
HAMMER
TOOL
BOX
DRAW
PINS,
2.0
mm
(500
per
pkg)
MOLDING
CLIPS
(500
per
pkg)
MANUAL
PULL
CLAMP
POWER
PULL
CLAMP
1
2
2
2
2
_1
1
6
1
2
2
1
1
1
1
1
1
1
1
1
2
Optional
Equipment
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Figure
A
Complete
Assembly
INSULATOR
SLEEVE
NUT,
brass
5/16-18
WASHER,
flat-brass
5/16
NUT,
hex-full
1/4-20
WASHER,
lock-split
1/4
WIRE,
braided
LABEL,
Auto
Arc
SCREW,
cap-socket
hd
10-32
x
1-3/4
CASE,
right
hand
WASHER,
flat-SAE
1/4
SCREW,
cap-hex
hd
1/4-20
x
3/4
TRANSFORMER
INSULATOR
PAPER
NUT,
hex
10-32
CASE,
left
hand
LABEL,
Auto
Arc
Pin
Welder
LABEL,
warning
AA
Pin
Welder
AC
LINE
CARD,
115
volts
w/strain
relief
&
terminal
TRIGGER
SWITCH,
480
volts
ac
20
amp
SCREW,
cap-socket
hd
10-32
x
3/4
CIRCUIT
BREAKER,
25
volts
ac
10
amp
TEFLON
INSULATOR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
118583
Page
2
  • Page 1 1
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  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
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  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14

Miller AUTO ARC PIN WELDER Owner's manual

Miller
Brand
Miller
Model
AUTO ARC PIN WELDER
Category
Welding System
Type
Owner's manual
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