Miller AASW 1510M Owner's manual

Miller
Brand
Miller
Model
AASW 1510M
Category
Welding System
Type
Owner's manual

This manual is also suitable for

auto_arc 7/93 − ST-145 104 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
October 1994 Form: OM-118 044C
Effective With Serial No. KE664390
AASW 1510M
Manually Operated, 1.5 kVA Portable Spot Welder
For Resistance Spot Welding
Rated Output Varies With Tong Length
Uses 110 V, 60 Hz, Single-Phase Input Power
Equipped With A 10 ft (3 m) Input Power Cord With Plug
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-118 044C − 10/94
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 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Dressing Tips 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Replacing Tips 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Changing Tongs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Cleaning Tongs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST
Figure 7-1. Main Assembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-2. Transformer, Power Main 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-3. Spot Welder Tips 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-118 044 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, 60 Hz, And 50% Duty Cycle
Input Power Cord 10 ft (3 m)
Overall Dimensions Length: 16 in (406 mm); Width: 4-1/2 in (114 mm); Height: 6 in (152 mm)
Work Capacity Combined Thickness
Mild Steel
1/8 in (3.2 mm)
Weight Net: 22 lb (10 kg) Ship: 26 lb (12 kg)
Options See Rear Cover
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)
*Calibrated with standard type tongs (see Figure 7-3)
OM-118 044 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 (see Section
5-2).
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-118 044 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-118 044 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
Ref. ST-800 156
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
2 Cord
3 Plug
Do not cut ground terminal off plug.
4 Grounded Receptacle
Connect plug to matching
grounded receptacle.
1
2
3
Model Size (AWG)
Input Conductor
Fuse/Circuit
Breaker Size
In Amperes
1.5 kVA 110 Volt No. 10 30
4
Figure 3-3. Input Power Connections
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
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.
ST-145 104
1
2
Figure 4-1. Hand Lever And Start Switch
OM-118 044 Page 5
Install &
Connect
Equipment
Begin Welding
Put On
Personal Safety
Equipment
Figure 4-2. 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
− −
5-2
Figure 5-1. Maintenance Schedule
5-2. 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.
5-3. 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.
OM-118 044 Page 6
5-4. Changing Tongs
For changing resistance spot welder tongs, see Section 3-1.
5-5. 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.
5-6. 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. − −
Low weld output. Check start switch S1 contacts for pitting and wear. Replace if nec-
essary.
− −
Check tip threads. Replace tips if necessary. 3-1
Replace or dress tips. 5-2, 5-3
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. 5-2, 5-3
Check input line voltage. − −
Clean work pieces. − −
Adjust tong pressure. 3-2
Burn through at point of weld. Shorten weld time. Figure 4-1
Adjust tong pressure. 3-2
Replace or dress tips. 5-2, 5-3
Realign tips. 3-1
OM-118 044 Page 7
SECTION 6 − ELECTRICAL DIAGRAMS
SA-162 467
Figure 6-1. Circuit Diagram For Spot Welders
OM-118 044 Page 8
SECTION 7 − PARTS LIST
1
2
3
4
5
6789
10
11
12
13
14
15
16
17
18
19
20
21
2223
24
25
26
27
28
29
30
31
32
33
34
35
363738
10 3
39
40
4142
45
46
44
43
3
ST-145 048
Fig 7-2
Figure 7-1. Main Assembly
OM-118 044 Page 9
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 7-1. Main Assembly
Quantity
1 019 643 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 601 865 NUT, stl hex full fnsh .250-20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 602 009 SCREW, cap stl sch .250-20 x 1.250 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 023 659 WIRING HARNESS, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 023 199 LEVER, operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 010 714 PIN, spring CS .312 x 1.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 010 712 LINK, tgl connecting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 010 713 PIN, spring CS .312 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 010 715 BOLT, pressure adjustment 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 601 876 NUT, stl hex jam .437-20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 010 668 SCREW, cap stl sch .250-20 x 1.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 017 668 HOLDER, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 010 709 CLAMP, tong top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 010 623 BRAID, tong set of four 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 010 716 CLAMP, connecting top tong braid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 602 008 SCREW, .250-20 x 1.000soc hexhd 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 601 854 NUT, al hex .375-24 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 095 297 STUD, stl .375-24 x 3.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 026 607 GUARD, spatter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 128 237 SCREW, 10-32 x .500hexwhd slt stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 602 262 HANDLE, wood 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 601 778 BOLT, crg stl .250-20 x 4.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 070 017 INSULATION, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 S1 *011 746 SWITCH, control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 291 CONTACT, assembly switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
023 987 CONTACT, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
011 292 TOGGLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
070 035 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 122 210 SCREW, 10-32 x .625hexwhd slt stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 026 759 INSULATOR, plug sec scr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 010 711 PIN, spring .375-3.00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 169 122 HOUSING, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 NAMEPLATE (order by model and style number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 602 024 SCREW, drive U 2 x 3/16 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 010 708 RETAINER, clamp tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 026 605 INSULATION, bottom clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 026 606 TUBING, fbr vulc .250 ID x .375 OD x .500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 026 604 INSULATION, fbr 1/32 in 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 602 004 SCREW, cap stl sch .250-20 x .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 010 707 CLAMP, bottom tong 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 039 052 CLAMP, threaded connecting tong braid. . . . . . . . . . . . . . . . . .
(included w/Item 5, Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 T1 +095 345 TRANSFORMER, pwr main (Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143 140 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 600 675 SPLICE, butt 16-14 wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 111 630 SCREW, 10-32 x .250hexwhd slt stl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 205 WASHER, lock stl intl tooth No. 10 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 019 642 COVER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 601 847 NUT, stl slflkg hex mscr 10-32 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 115 104 CONNECTOR, clamp cable 1/2 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 094 503 CABLE, pwr 10ft 16ga 3/C 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 026 763 TUBING, gl acrylic No. 7 x 2.500 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 128 237 SCREW, 10-32 x .500hexwhd slt stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+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.
OM-118 044 Page 10
Replace Coils At Factory Or Factory Authorized Service Station
Description
Part
No.
095 347
Item
No.
Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38)
Quantity
1 026 601 INSULATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 095 312 COIL, pri 110V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 157 STUD, stl No. 10-32 x 8.125 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 137 943 NUT, core stud 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 +033 123 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 SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Flat
(89 mm)
6-1/2” (165 mm)
3-1/2”
Standard Flat
040 211 040 212
Standard Flat
040 211 040 212
STANDARD
TT-6
(190 mm)
7-1/2”
Standard
040 211 040 212
G-7
Ref. S-0550
6” (152 mm) 040 197
12” (305 mm) 040 198
18” (457 mm) 040 199
12” (305 mm) 040 203
18” (457 mm) 040 204
8” (203 mm) 040 207
Figure 7-3. Spot Welder Tongs And Tips
Effective January 1, 1997
(Equipment with a serial number preface of “KH” or newer)
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, warrants to its original retail purchaser that new
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped from factory. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, manufacturer will
repair or replace any warranted parts or components that fail
due to such defects in material or workmanship.
Manufacturer must be notified in writing within thirty (30) days
of such defect or failure, at which time manufacturer will
provide instructions on the warranty claim procedures to be
followed.
Manufacturer shall honor warranty claims on warranted
equipment listed below in the event of such a failure within the
warranty time periods. All warranty time periods start on the
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
distributor.
1. 5 Years Parts − 3 Years Labor
* Original main power rectifiers
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Robots
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor
* Motor Driven Guns (w/exception of Spoolmate 185)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* Orbital Weld Heads
* Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
* SDX Transformers
* Running Gear/Trailers
* Field Options
(NOTE: Field options are covered under the limited
warranty for the remaining warranty period of the
product they are installed in, or for a minimum of one
year — whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts
* Spoolmate 185
Limited Warranty shall not apply to:
1. Items furnished by manufacturer, but manufactured by
others, such as engines or trade accessories. These
items are covered by the manufacturer’s warranty, if
any.
2. Consumable components; such as contact tips, cutting
nozzles, contactors, relays, brushes, slip rings, or parts
that fail due to normal wear.
3. Equipment that has been modified by any party other
than manufacturer, or equipment that has been
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has
not had reasonable and necessary maintenance, or
equipment which has been used for operation outside of
the specifications for the equipment.
MANUFACTURER’S PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL
USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING
EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at manufacturers option: (1)
repair; or (2) replacement; or, where authorized in writing by
manufacturer in appropriate cases, (3) the reasonable cost
of repair or replacement at an authorized service station; or
(4) payment of or credit for the purchase price (less
reasonable depreciation based upon actual use) upon return
of the goods at customer’s risk and expense. manufacturer’s
option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at an authorized service
facility as determined by manufacturer. Therefore no
compensation or reimbursement for transportation costs of
any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MANUFACTURER IS
EXCLUDED AND DISCLAIMED BY MANUFACTURER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
brand_warr 5/97
Warranty
PRINTED IN USA
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Owner’s Manuals
Circuit Diagrams
Contact the Delivering Carrier
for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
Resources Available
Owner’s Record
File a claim for loss or damage during ship-
ment.
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Miller AASW 1510M Owner's manual

Miller
Brand
Miller
Model
AASW 1510M
Category
Welding System
Type
Owner's manual
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