Miller KE14 Owner's manual

Brand: Miller

Model: KE14

Category: Welding System

Type: Owner's manual

This manual is also suitable for

cover 1/94 − ST-146 013 PRINTED IN USA

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

manufacturer’s 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.

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

1 2

CAUTION

MOVING PARTS can injure.

• Do not put hands between tips.

• Keep away from pinch points.

• Keep guards in place.

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:

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.

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.

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

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

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.

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.

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

Blow Out

Vacuum

Unit

Replace

Unreadable

Labels

6 Months

Inspect

Tips

See

Section

− −

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)

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

678 9

17 18

2425

3536

3738

40414243

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .