Miller LMSW-52T Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

cover 1/94 ST-146 013 PRINTED IN USA
© 1994 MILLER Electric Mfg. Co.
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
March 1994 Form: OM-708D
Effective With Style No. KE-14
Manually Operated, 1.5 kVA And 2.5 kVA Portable Spot Welders
For Resistance Spot Welding
Rated Output Varies With Tong Length
Models Use 110 Or 220 V, 50/60 Hz, Single-Phase Input Power
Equipped With 10 ft (3 m) Input Power Cord With Plug
Equipped With 0 To 5 Second Spot Timer
MSW-41T, MSW-42T,
And LMSW-52T
sr4 4/93
RESISTANCE SPOT WELDING SAFETY PRECAUTIONS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In resistance spot welding, as in most jobs, exposure to certain hazards occurs. Spot welding is safe when
precautions are taken. The safety information given below is only a summary of the more complete safety
information that will be found in the Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
SPOT WELDING can be hazardous.
RESISTANCE SPOT WELDING can
cause fire or explosion.
Sparks can fly off from the weld. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not spot weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the weld. If this is
not possible, tightly cover them with approved covers.
4. Be alert that welding sparks can easily go through small cracks
and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Do not spot weld on closed containers such as tanks or drums.
7. Do not weld where atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
8. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
9. After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
10. Do not exceed the equipment rated capacity.
11. Use only correct fuses or circuit breakers. Do not oversize or
bypass them.
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.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Disconnect input power before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29
CFR 1910.147 (see Safety Standards).
4. Properly install and ground this equipment according to this
manual and national, state, and local codes.
5. Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug
is connected to a properly grounded receptacle outlet always
double-check the supply ground before applying power.
6. When making input connections, attach the grounding conductor
first.
7. Keep cords dry, free of oil and grease, and protect from hot metal
and sparks.
8. Frequently inspect input power cord and ground conductor for
damage replace immediately if damaged. Check ground
conductor for continuity.
9. Turn off all equipment when not in use.
10. For water-cooled equipment, check and repair or replace any
leaking hoses or fittings. Do not use any electrical equipment if
you are wet or in a wet area.
11. Use only well-maintained equipment. Repair or replace
damaged parts at once.
12. Wear a safety harness if working above floor level.
13. Keep all panels, covers, and guards securely in place.
SPARKS can cause injury.
Very often sparks fly off from the joint area.
1. Wear approved face shield or safety goggles with side shields.
2. 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.
3. 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.
HOT METAL can cause burns.
Wear gloves or allow cooling period before servicing
tongs or tips.
1. Always wear welding-type, insulated gloves when using this
equipment.
2. Do not touch workpiece, tips, or tongs with bare hands.
MOVING PARTS can cause injury.
The tong tips, tongs, and linkages move during
operation.
1. Keep away from moving parts.
2. Keep away from pinch points.
3. Do not put hands between tips.
4. Keep all guards and panels securely in place.
FUMES can be hazardous to your
health.
Coatings, cleaners, paints, and platings can produce
fumes when welded. Breathing these fumes can be
hazardous to your health.
1. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the weld to
remove fumes.
3. In confined spaces, use an approved air-supplied respirator.
4. Do not weld on metals, such as galvanized, lead, or cadmium
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.
5. Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, coatings, and cleaners.
sr4 4/93
OM-708D 3/94
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 Superinten-
dent 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.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, 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.
EMF INFORMATION
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1* 4/93
TABLE OF CONTENTS
SECTION 1 SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 SPECIFICATIONS
2-1. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INSTALLATION
3-1. Tong And Tip Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Tong Pressure Adjustment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting Input Power 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection For 220 Volts Model 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Dressing Tips 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Replacing Tips 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Changing Tongs 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Cleaning Tongs 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ELECTRICAL DIAGRAMS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 PARTS LIST
Figure 7-1. Main Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-2. Transformer, Power Main 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-3. Timer, Spot (230V Illustrated) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 7-1. Spot Welder Tips 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-708 Page 1
SECTION 1 SAFETY INFORMATION
mod1.2 4/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation not related to safety.
2
NOTE
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
Do not put hands between tips.
Keep away from pinch points.
Keep guards in place.
3
Turn Off switch before checking pressure.
Figure 1-1. Safety Information
SECTION 2 SPECIFICATIONS
Table 2-1. Resistance Spot Welders
Specification Description
Welding Process Resistance Spot Welding
Type Of Input Power Single-Phase; 110 Volts AC, 50/60 Hz, And 220 Volts AC, 50/60 Hz, 50% Duty Cycle
Input Power Cord Input Power Cord 10 ft (3 m)
Overall Dimensions Spot Welder Length: 16 in (406 mm); Width: 4-1/2 in (114 mm); Height: 6 in (152 mm)
Control Box Length: 6-3/4 in (171 mm); Width: 11 in (279 mm); Height: 11 in (279 mm)
Options See Rear Cover
Model
1.5 KVA, 110 V 1.5 KVA, 220 V 2.5 KVA, 220 V
Work Capacity Combined
Thickness Mild Steel
1/8 in (3.2 mm) 1/8 in (3.2 mm) 3/16 in (4.7 mm)
Weight Net: 34 lb (15.4 kg)
Ship: 38 lb (17.2 kg)
Net: 34 lb (15.4 kg)
Ship: 38 lb (17.2 kg)
Net: 42 lb (19.1 kg)
Ship: 45 lb (20.4 kg)
Rated Output Amperes*
Model 6 in (152 mm) Tongs 12 in (305 mm) Tongs 18 in (457 mm) Tongs Tong Gap
1.5 kVA, 110 Volts 5500 4500 3600 3-1/2 in (89 mm)
1.5 kVA, 220 Volts 5500 4500 3600 3-1/2 in (89 mm)
2.5 kVA, 220 Volts 6750 5800 4850 3-1/2 in (89 mm)
*Calibrated with standard type tongs (see Chart 7-1)
OM-708 Page 2
2-1. Duty Cycle
CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
Do not exceed 50% duty cycle.
warn7.1* 2/92
The duty cycle of a resistance spot welder is the percentage of a one minute period that a resistance spot welder can
be operated without causing overheating or damage to the unit. These resistance spot welders are rated at 50% duty
cycle, which means that they can be operated for thirty seconds out of every minute.
SECTION 3 INSTALLATION
3-1. Tong And Tip Installation
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug from receptacle before inspecting or installing.
Allow tongs and tips to cool before touching.
Keep tips dressed down to within a 1/8 in (3.2 mm) diameter or less for 1.5 kVA
models, and to within 5/32 in (4 mm) diameter or less for 2.5 kVA models (see
Section 5-3).
Be sure ends of tongs are clean and free of corrosion before installing.
NOTE
ST-800 154 / ST-800 155-A
1Tip
2 Tip Threads
3 Tong
Coat tip threads with supplied heat
sink compound, thread tip into tong,
and tighten. Do not overtighten. Re-
peat procedure for remaining tip.
Bottom Tong Installation:
4 Bottom Tong
5 Hole In Spatter Guard
6 Insulator Plug
7 Bottom Tong Securing Screw
Loosen the four (4) screws.
Slide tong through hole in spatter
guard, and into bottom tong holder
as far as possible, and position tong
so that tip is pointing straight up.
Tighten screws to lock tong in
place.
Top Tong Installation:
8 Top Tong
9 Top Tong Holder/Pivot Casting
10 Top Tong Securing Screw
Loosen the four (4) screws.
Slide tong into pivot casting as far
as necessary, so that tip mates with
bottom tip when tongs are closed.
Tighten screws to lock tong in
place.
3/16 in
9/16 in
Tools Needed:
4
5
6
8
9
10
1
2
3
7
Figure 3-1. Tong And Tip Installation
OM-708 Page 3
3-2. Tong Pressure Adjustment
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting or installing.
Allow tongs and tips to cool before touching.
EXCESSIVE TONG PRESSURE can
damage tips.
Do not use tongs as a clamp or vice to hold
workpiece together.
If the two pieces of material to be welded do not make
good contact at the point of the intended weld, clamp
material to provide good contact between surfaces.
WARNING
Tong pressure is adjustable, and must be checked and/or set before operation.
Correct tong pressure is necessary to create a quality weld and to prevent damage
to tips.
Too much tong pressure causes the weld nugget to dimple and material to 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.
NOTE
Ref. ST-800 156
1 Front Nut
2 Rear Nut
3 Pivot Casting
4 Hand Lever
5 Tongs
To increase tong pressure, loosen
front nut. The farther the front nut is
turned out, the greater the pressure
on the tips when the hand lever is
closed. Turn the rear nut up to the
pivot casting to lock the position.
To decrease tong pressure, loosen
the rear nut and turn the front nut up
to the pivot casting.
6 Machine Screw
The farther down the screw is
turned, the farther the hand lever
will close. Adjustment of this screw
will determine if the tongs lock on
the material, or just pull up tight. Ad-
just screw to allow lever to be raised
easily after the weld has been com-
pleted.
1
2
3
4
5
6
11/16 in
Tools Needed:
Figure 3-2. Tong Pressure Adjustment
OM-708 Page 4
3-3. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not cut ground terminal off plug.
Input supply wiring and receptacle must meet National Electrical Code and all other codes.
swarn3.1* 2/93
ST-800 233
Operate spot welder from a sepa-
rately fused or circuit breaker pro-
tected circuit, and use correct size
input conductors (see Table for cor-
rect size).
1 Rating Label (Not Visible As
Shown On Spot Welder)
2 Cord
3 Parallel Plug On 110 Volts AC
Models
4 Tandem Plug On 220 Volts
AC Models
Do not cut ground terminal off plug.
5 Grounded Receptacle
Connect plug to matching
grounded receptacle.
1
2
3
4
5
Or
Model
Size (AWG)
Input Conductor
Fuse/Circuit
Breaker Size
In Amperes
1.5 kVA 110 Volt
1.5 kVA 220 Volt
2.5 kVA 220 Volt
No. 10
No. 12
No. 10
30
15
30
1
Figure 3-3. Input Power Connections
OM-708 Page 5
SECTION 4 OPERATION
ELECTRIC SHOCK can kill.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrical parts.
Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
Keep your head out of the fumes.
Ventilate area, or use suction device at weld area.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for metals, coatings,
and cleaners.
WELDING can cause fire or explosion.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Allow work and equipment to cool before handling.
Do not locate unit over combustible surfaces.
Protect area and persons from flying sparks.
SPARKS AND HOT METAL can injure.
Wear face shield or safety goggles.
Wear body protection.
Allow tips and work to cool before handling.
MOVING PARTS can injure.
Do not put hands between tips.
Keep away from pinch points.
Keep guards in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near resistance spot welding operations.
See Safety Precautions at beginning of manual for ba-
sic welding safety information.
WARNING
swarn6.1* 10/91
ST-146 013
1 Power Switch
2 Spot Weld Timer
3 Hand Lever
4 Start Switch
1
2
3
4
Figure 4-1. Controls (220 Volts Model Shown)
Ref. ST-145 104
1 Hand Lever
Use lever to open and close tongs.
See Section 3-2 for tong pressure
adjustment. Closing the hand lever
compresses the material between
the tips during the welding process.
2 Start Switch
Use switch to turn weld current On
and Off. Move switch sideways in
either direction to start weld current.
Release switch to stop weld cur-
rent.
1
2
Figure 4-2. Hand Lever And Start Switch
OM-708 Page 6
Ref. ST-800 233
1 Spot Weld Timer
Use control as a way to select the
amount of time to make the spot
weld. The weld time may be ad-
justed from 0 to 5 seconds.
Weld time begins when the start
switch is closed (see Figure 4-2).
When the time set on the timer has
ended, or the start switch is re-
leased, weld output stops, and re-
sets for another weld cycle. A light
in the timer turns off when the cycle
has ended.
2 Power Switch
Use switch to turn unit On and Off.
1
2
Figure 4-3. Spot Weld Timer And Power Switch
Install &
Connect
Equipment
Set Control &
Turn On Unit
Put On
Personal Safety
Equipment
Begin Welding
Figure 4-4. Sequence Of Resistance Spot Welding
SECTION 5 MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining or servicing.
MOVING PARTS can injure.
Do not put hands between tips.
Keep away from pinch points.
Maintenance to be performed only by qualified persons.
swarn8.1* 2/93
5-1. Routine Maintenance
Turn Off all power before maintaining.
Ref. ST-800 156
3 Months
OR
Blow Out
Or
Vacuum
Unit
Replace
Unreadable
Labels
6 Months
Inspect
Tips
See
Section
7
5-3
Figure 5-1. Maintenance Schedule
OM-708 Page 7
5-2. Overload Protection For 220 Volts Model
Ref. ST-800 233 / Ref. ST-800 185-A
Turn Off unit and disconnect input
power.
If fuse opens, unit shuts down. To
replace fuse proceed as follows:
1 Fuse Holder Cover
2 Fuse F1 (See Parts List For
Rating)
1
2
Figure 5-2. Fuse F1 Location
5-3. Dressing Tips
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Use a tip dresser according to its instructions. Do not file tips unless qualified. Incorrect filing methods can result in
mismatched tips and poor quality welds. A file can be used to remove the “mushroom” from the tips if filing is confined
to the tapered sides of the tips.
5-4. Replacing Tips
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
To replace tip, remove present tip and go to Section 3-1.
5-5. Changing Tongs
For changing resistance spot welder tongs, see Section 3-1.
5-6. Cleaning Tongs
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Wipe both tongs and tong holders clean. Bends or nicks near the tong ends that insert into the tong holders may reduce
the maximum efficiency and capacity of the spot welder. If corroded, polish tongs with crocus cloth.
OM-708 Page 8
5-7. Troubleshooting
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
Allow cooling period before servicing.
MOVING PARTS can injure.
Do not put hands between tips.
Keep away from pinch points.
Troubleshooting to be performed only by qualified
persons.
swarn9.1* 4/92
Table 5-1. Welding Trouble
Trouble Remedy Section
No weld output. Check line fuses, and replace if necessary.
For 220 V models, check fuse F1, and replace if necessary. 5-2
Low weld output. Check power switch S1 and/or start switch. Replace if necessary.
Check tip threads. Replace tips if necessary. 3-1
Replace or dress tips. 5-3, 5-4
Remove tongs. Remove insulator plugs from front housing, and
blow out tong clamps with compressed air.
3-1
Longer than normal Weld Time required. Replace or dress tips. 5-3, 5-4
Check input line voltage.
Clean work pieces.
Adjust tong pressure. 3-2
Burn through at point of weld. Shorten weld time. Figure 4-3
Adjust tong pressure. 3-2
Replace or dress tips. 5-3, 5-4
Realign tips. 3-1
OM-708 Page 9
SECTION 6 ELECTRICAL DIAGRAMS
SA-162 466
Figure 6-1. Circuit Diagram For 110 Volts Models
SA-072 065-A
Figure 6-2. Circuit Diagram For 220 Volts Model
OM-708 Page 10
SECTION 7 PARTS LIST
1
2
3
4
5
678 9
10
11
12
13
14
15
16
17 18
3
10
19
20
21
22
23
2425
26
27
28
29
30
31
32
33
34
3536
3
3738
39
40414243
44
20
Fig 7-2
Ref. ST-145 048
Figure 7-1. Main Assembly
OM-708 Page 11
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 7-1. Main Assembly
Quantity
Model
41T 42T 52T
1 019 643 HANDLE, carrying 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 019 646 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 601 865 NUT, stl hex full fnsh .250-20 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 602 009 SCREW, cap stl sch .250-20 x 1.250 7 7 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 023 659 WIRING HARNESS, switch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 023 660 WIRING HARNESS, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 023 199 LEVER, operating 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 082 090 LEVER, operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 010 714 PIN, spring CS .312 x 1.750 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 712 LINK, tgl connecting 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 010 713 PIN, spring CS .312 x 1.250 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 010 715 BOLT, pressure adjustment 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 601 876 NUT, stl hex jam .437-20 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 010 668 SCREW, cap stl sch .250-20 x 1.500 2 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 017 668 HOLDER, tong top 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 010 709 CLAMP, tong top 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 010 623 BRAID, tong set of four 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 010 716 CLAMP, connecting top tong braid 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 602 008 SCREW, mach stl rdh 10-32 x .250 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 601 854 NUT, al hex .375-24 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 095 297 STUD, stl .375-24 x 3.750 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 026 607 GUARD, spatter 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 128 237 SCREW, hexwhd-slt stl slffmg 10-32 x .500 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 602 262 HANDLE, wood 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 601 778 BOLT, crg stl .250-20 x 4.500 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 070 017 INSULATION, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 S1 *011 746 SWITCH, control (consisting of) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 291 CONTACT, assembly switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
023 987 CONTACT, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 292 TOGGLE, switch 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
070 035 BASE 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 122 210 SCREW, hexwhd stl slffmg 10-32 x .625 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 026 759 INSULATOR, plug sec scr 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 010 711 PIN, spring .375-3.00 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 017 667 HOUSING, front 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 NAMEPLATE, (order by model and style number) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 602 024 SCREW, drive U 2 x 3/16 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 010 708 RETAINER, clamp tong 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 026 605 INSULATION, bottom clamp 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 026 606 TUBING, fbr vulc .250 ID x .375 OD x .500 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 026 604 INSULATION, fbr 1/32 in 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 602 004 SCREW, cap stl sch .250-20 x .750 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 010 707 CLAMP, bottom tong 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 039 052 CLAMP, threaded connecting tong braid. . . . . . . . . . . . . . . . . .
(included w/Item 5, Fig 7-2) 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 345 TRANSFORMER, pwr main 110V (Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 350 TRANSFORMER, pwr main 220V (Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 354 TRANSFORMER, pwr main 220V (Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143 140 LABEL, warning general precautionary 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 600 675 SPLICE, butt 16-14 wire 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 111 630 SCREW, hexwhd-slt stl 10-32 x .250 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 019 642 COVER 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 601 847 NUT, stl slflkg hex mscr 10-32 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 115 104 CONNECTOR, clamp cable 1/2 in 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 026 763 TUBING, gl acrylic No. 7 x 2.500 3 3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 12
Replace Coils At Factory Or Factory Authorized Service Station.
Description
Part
No.
Item
No.
Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38)
095 345 095 350 095 354
Quantity
Model
41T 42T 52T
1 026 601 INSULATION 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 026 602 INSULATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 312 COIL, pri 115V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 309 COIL, pri 230V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 308 COIL, pri 230V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 157 STUD, stl No. 10-32 x 8.125 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 156 STUD, stl No. 10-32 x 11.125 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 137 943 NUT, core stud 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 +033 123 BAR, sec 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 +033 122 BAR, sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
ST-141 482-A
Figure 7-2. Transformer, Power Main
+Item 37 on Figure 7-1 is included when ordering these items as replacement parts.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 13
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 7-3. Timer, Spot (230V Illustrated)
Quantity
Model
115V 230V
041 081 041 082
1 NAMEPLATE, (order by model and style numbers) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 S1 124 511 SWITCH, tgl DPST 40A 600VAC 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 W 605 855 CONTACTOR, 40A 3P (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
032 349 COIL, 115V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
034 260 LINK, connecting contactor terminal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 032 152 CABINET 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 072 042 BAFFLE 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 T2 605 856 TRANSFORMER, control 230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 168 308 PANEL, front 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 TD1 605 952 TIMER, delay reset 5sec 120V 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 046 432 HOLDER, fuse 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 F1 *012 653 FUSE, mintr gl .5A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 603 110 HOSE, nprn .500 ID x .687 OD (order by ft) 1ft 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 157 BLANK, snap-in metal .500mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 600 342 CORD, No. 16 4/c (order by ft) 10ft 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 PLG1 023 618 CORD SET, 115V 16ga 3/c 600V 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 PLG1 023 625 CORD SET, 230V 16ga 3/c 600V 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 010 610 CONNECTOR, cable clamp .500 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
23 4
5
6
7
8
9101112
13
14
ST-146 012-B
Figure 7-3. Timer, Spot (230V Illustrated)
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 14
Chart 7-1. Spot Welder Tips
Flat
Flat
(89 mm)
(89 mm)
6-1/2” (165 mm)
3-1/2”
3-1/2”
Standard Flat
040 211 040 212
MO
Offset
040 215
Standard Flat
040 211 040 212
Standard
040 211 040 212
FF
040 213
FH
040 214
STANDARD
MO OFFSET
TT-6
TT-9
FF
FH
(190 mm)
7-1/2”
Standard
040 211 040 212
G-7
S-0550
9-1/2”
(241 mm)
6” (152 mm) 040 197
12” (305 mm) 040 198
18” (457 mm) 040 199
6” (152 mm) 040 200
12” (305 mm) 040 201
18” (457 mm) 040 202
12” (305 mm) 040 203
18” (457 mm) 040 204
12” (305 mm) 040 205
18” (457 mm) 040 206
8” (203 mm) 040 208
5” (127 mm) 040 209
8” (203 mm) 040 207
9/93
OPTIONS AND ACCESSORIES
SWP-2 SPOT WELDER
PEDESTAL
(#040 872)
Leaves hands free to handle the
work. When foot control is
depressed, tongs close and Start
Switch is activated.
SPOT WELD TIMER
(#041 081) MSW-41
(#041 082) MSW-42 and
LMSW-52
Cannot be used on “T” model
units. Provides 05 second
mechanical weld timer.
GYRO BAIL
(#041 979)
Supports weight of welder.
Operates with boom and
counterweight or from spring-
loaded cable. Spot welds in any
position.
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Miller LMSW-52T Owner's manual

Category
Welding System
Type
Owner's manual
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