OM-1308 144212M

December 1997
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding

Description

Arc Welding Power Source And Wire

Feeder

Millermatic 250

Visit our website at

www.MillerWelds.com
 TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual: SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MIG = GMAW 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-4. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-6. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-7. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-8. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-9. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-11. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-12. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. Installing Receptacle Module For Use With A Spool Gun (Optional) . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5. Installing Drive Roll And Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-6. Aligning Drive Rolls And Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-7. Unicable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-8. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-9. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 6 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPTIONS AND ACCESSORIES
WARRANTY
 SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means Note; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to D If earth grounding of the workpiece is required, ground it directly
call attention to and identify possible hazards. When you see with a separate cable do not use work clamp or work cable.
the symbol, watch out, and follow the related instructions to D Do not touch electrode if you are in contact with the work, ground,
avoid the hazard. The safety information given below is only or another electrode from a different machine.
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all D Use only well-maintained equipment. Repair or replace damaged
Safety Standards. parts at once. Maintain unit according to manual.
Y Only qualified persons should install, operate, maintain, and D Wear a safety harness if working above floor level.
repair this unit. D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away. D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
ELECTRIC SHOCK can kill. contact with any metal object.
D Do not connect more than one electrode or work cable to any
Touching live electrical parts can cause fatal shocks single weld output terminal.
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input SIGNIFICANT DC VOLTAGE exists after removal of
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the input power on inverters.
wire, wire reel, drive roll housing, and all metal parts touching the D Turn Off inverter, disconnect input power, and discharge input
welding wire are electrically live. Incorrectly installed or improperly capacitors according to instructions in Maintenance Section
grounded equipment is a hazard. before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
FUMES AND GASES can be hazardous.
or covers big enough to prevent any physical contact with the work
or ground. Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Do not use AC output in damp areas, if movement is confined, or if health.
there is a danger of falling.
D Use AC output ONLY if required for the welding process. D Keep your head out of the fumes. Do not breathe the fumes.
D If AC output is required, use remote output control if present on D If inside, ventilate the area and/or use exhaust at the arc to remove
unit. welding fumes and gases.
D Disconnect input power or stop engine before installing or D If ventilation is poor, use an approved air-supplied respirator.
servicing this equipment. Lockout/tagout input power according to D Read the Material Safety Data Sheets (MSDSs) and the
OSHA 29 CFR 1910.147 (see Safety Standards). manufacturers instructions for metals, consumables, coatings,
D Properly install and ground this equipment according to its cleaners, and degreasers.
Owners Manual and national, state, and local codes. D Work in a confined space only if it is well ventilated, or while
D Always verify the supply ground check and be sure that input wearing an air-supplied respirator. Always have a trained watch-
power cord ground wire is properly connected to ground terminal in person nearby. Welding fumes and gases can displace air and
disconnect box or that cord plug is connected to a properly lower the oxygen level causing injury or death. Be sure the breath-
grounded receptacle outlet. ing air is safe.
D When making input connections, attach proper grounding conduc- D Do not weld in locations near degreasing, cleaning, or spraying op-
tor first double-check connections. erations. The heat and rays of the arc can react with vapors to form
D Frequently inspect input power cord for damage or bare wiring highly toxic and irritating gases.
replace cord immediately if damaged bare wiring can kill. D Do not weld on coated metals, such as galvanized, lead, or
D Turn off all equipment when not in use. cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
D Do not use worn, damaged, undersized, or poorly spliced cables. air-supplied respirator. The coatings and any metals containing
D Do not drape cables over your body. these elements can give off toxic fumes if welded.

OM-1308 Page 1
 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.

OM-1308 Page 2
1-3. Additional Symbols for Installation, Operation, and Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories. D High-frequency (H.F.) can interfere with radio
D Use equipment of adequate capacity to lift and navigation, safety services, computers, and
support unit. communications equipment.
D If using lift forks to move unit, be sure forks are D Have only qualified persons familiar with
long enough to extend beyond opposite side of electronic equipment perform this installation.
unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
OVERUSE can cause OVERHEATING D If notified by the FCC about interference, stop using the
equipment at once.
D Allow cooling period; follow rated duty cycle. D Have the installation regularly checked and maintained.
D Reduce current or reduce duty cycle before D Keep high-frequency source doors and panels tightly shut, keep
starting to weld again. spark gaps at correct setting, and use grounding and shielding to
D Do not block or filter airflow to unit. minimize the possibility of interference.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts. ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
MOVING PARTS can cause injury. such as robots.
D Be sure all equipment in the welding area is
D Keep away from moving parts. electromagnetically compatible.
D Keep away from pinch points such as drive D To reduce possible interference, keep weld cables as short as
rolls. possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury. D Be sure this welding machine is installed and grounded
according to this manual.
D Do not press gun trigger until instructed to do D If interference still occurs, the user must take extra measures
so. such as moving the welding machine, using shielded cables,
D Do not point gun toward any part of the body, using line filters, or shielding the work area.
other people, or any metal when threading
welding wire.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, CSA Standard W117.2, from
20402. Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American Safe Practices For Occupation And Educational Eye And Face
Welding Society Standard AWS F4.1, from American Welding Society, Protection, ANSI Standard Z87.1, from American National Standards
550 N.W. LeJeune Rd, Miami, FL 33126 Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Protec- Cutting And Welding Processes, NFPA Standard 51B, from National
tion Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1308 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committees judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.

OM-1308 Page 4
 SECTION 2 INSTALLATION

2-1. Specifications
Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase
Circuit
Rated Output Voltage 200 V 220 V 230 V 380 V 415 V 460 V 575 V KVA KW
250 A at 28 VDC, 200 A at 28 VDC, 32 50 45 44 26 24 22 18 10 7.7
40% Duty Cycle 60% Duty Cycle 2.3* 2.2* 2* 1.3* 1.2* 1* 0.8* 0.46* 0.13*
Wire Type and Diameter Wire Feed Speed Dimensions Net Weight
Solid Steel Stainless Steel Flux Cored 50670 IPM H: 37 in (940 mm) 225 lb
(1.21.7 m/min) W: 19 in (483 mm) (102 kg)
.023 .045 in .023 .035 in .030 .045 in D: 30-1/4 in (768 mm)
(0.6 1.2 mm) (0.6 0.9 mm) (0.8 1.2 mm)
* While idling

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.

60% Duty Cycle At 200 Amperes 40% Duty Cycle At 250 Amperes

6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes

duty1 4/95 SB-150 215

OM-1308 Page 5
2-3. Volt-Ampere Curves
1 Normal Volt-Ampere Curves
The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output capa-
bilities of the welding power source.
Curves of other settings fall be-
1 tween the curves shown.
2 Overload Volt-Ampere Curves
When unit is used beyond capacity,
circuitry senses the overload and
shuts down unit output. Release
trigger and lower weld voltage set-
ting before trying to weld. This shut
down circuitry protects internal
circuits and parts from overload
damage.

60

50
2
40
DC VOLTS

30
*
*
20

10
*Approximate shutdown voltage/amperage
0 points shown for reference only.
0 50 100 150 200 250 300 350 400

DC AMPERES
ssb1.1 10/91 SB-144 925 / S-0700

2-4. Installing Work Clamp

1 Work Cable
2 Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
3 Negative () Output Terminal
Connect cable to terminal and
cover connection with boot.
4 4 Hardware
5 Work Clamp
Route cable through clamp handle
and secure as shown.
5
Close door.

1
2

Tools Needed:
1/2, 3/4 in
ST-150 228-E

OM-1308 Page 6
2-5. Installing Welding Gun
1 Drive Assembly
1
2 Gun Securing Knob
3 Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
2 knob.
4 4 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.

Ref. ST-150 256-D

2-6. Setting Gun Polarity For Wire Type

. Always read and follow wire manufacturers recommended polarity, and see label inside unit by wire drive assembly.
Tools Needed: 3/4 in

2-7. Installing Gas Supply

Obtain gas cylinder and chain to
running gear, wall, or other station-
1 ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
2
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3 3 Cylinder
4 Regulator/Flowmeter
4 Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
Argon Gas
6 Welding Power Source Gas
1
Hose Connection
Connect customer supplied gas
OR hose between regulator/flowmeter
gas hose connection, and fitting on
2 rear of welding power source.
7
5 7 Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire man-
3 ufacturers recommended flow
8 9 rate.
8 CO2 Adapter (Customer Sup-
plied)
CO2 Gas
9 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.
6
Tools Needed:
1-1/8, 5/8 in
Ref. ST-148 265-B / ST-802 028

OM-1308 Page 7
2-8. Installing Wire Spool And Adjusting Hub Tension

Use compression spring with

8 in (200 mm) spools.

When a slight force is needed to turn spool, tension is set.

Tools Needed:

15/16 in ST-072573-B

2-9. Positioning Jumper Links

Check input voltage available at
site.
1 Jumper Links Access Door
Open door.
200 VOLTS 230 VOLTS 220 VOLTS
2 Jumper Link Label
3 Check label only one is on unit.
3 Input Voltage Jumper Links
230 VOLTS 460 VOLTS 380 VOLTS
Move jumper links to match input
voltage.
Close and secure access door.
460 VOLTS 575 VOLTS 415 VOLTS

S-144 918-C S-144 916-A S-144 915-A

1 2

Tools Needed:

3/8 in
Ref. ST-148 263-C

OM-1308 Page 8
2-10. Electrical Service Guide
Input Voltage 200 220 230 380 415 460 575

Input Amperes At Rated Output 50 45 44 26 24 22 17

Max Recommended Standard Fuse Or Circuit

80 70 70 40 35 35 25
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 8 10 10 12 12 10 12

Max Recommended Input Conductor Length

93 (28) 75 (23) 82 (25) 137 (42) 163 (50) 329 (100) 313 (95)
In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil 8 10 10 12 12 10 12

Reference: 1996 National Electrical Code (NEC). S-0092J

2-11. Selecting A Location And Connecting Input Power

Have only qualified persons make
this installation.
1 Rating Label
Supply correct input power.
Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
18 in (457 mm) Section 20.
for airflow

GND/PE

GND/PE
Connect First L1 L2

Size and ratings must comply with ap-

1 plicable codes. Install conductors in
conduit or equivalent into a deener-
gized line disconnect device.

ST-801 721

OM-1308 Page 9
2-12. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
4 7 Gun Conduit Cable
Lay gun cable out straight.
7

Tools Needed:

1 2 3 5 6

. Hold wire tightly to keep it

from unraveling.

6 in 4 in
(150 mm) (102 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.

Tighten

Close and tighten pressure Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.

WOOD

Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Close
comes out of gun. Reinstall Tighten knob enough to prevent slipping. and latch door.
contact tip and nozzle
Ref. ST-148 261-C / ST-159 218-B / ST-801 083 / S-0627-A

OM-1308 Page 10
 SECTION 3 OPERATION

3-1. Controls
1 Wire Speed Control
The scale around the control is per-
cent, not wire feed speed.
2 Voltage Switch
2 The scale around the control is
actual voltage.
3 Low Range/Full Range Switch
1
Use Low Range when wire speed is
between 50 and 350 ipm.
4 Pilot Light
5 Power Switch
3

Ref. ST-148 579-A / Ref. ST-174 835-A

3-2. Installing Receptacle Module For Use With A Spool Gun (Optional)
Remove existing options panel.
1 Module
2 Plug PLG9
3 Plug PLG7
3 Connect PLG9 to PLG7.
2 Slide module into upper front panel
where options panel was removed.
1 Secure with screws.
See Options and Accessories
page at end of manual, or contact
your Factory Authorized Service
Agent for details.

Tools Needed:

ST-801 732

OM-1308 Page 11
 SECTION 4 MAINTENANCE AND TROUBLESHOOTING
4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace unreadable labels. Repair or replace

cracked weld cable.

Clean and tighten weld terminals.

6 Months

Blow out or vacuum inside. during Remove drive roll and

heavy service clean monthly. carrier. Apply light coat
of oil or grease to drive
OR motor shaft.

4-2. Circuit Breaker CB1

1 Circuit Breaker CB1
If CB1 opens, wire feeding stops.
2 Welding Gun
Check gun liner for blockage or
1 kinks.
3 Wire Drive Assembly
Check for jammed wire, binding
drive gear or misaligned drive rolls.
2 Allow cooling period and reset
breaker. Close door.

Ref. ST-148 261-C

4-3. Unit Overload

If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun
trigger to reset this condition.

OM-1308 Page 12
4-4. Replacing Gun Contact Tip
Y Turn Off power.
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
2 contact tip. Reinstall nozzle.

Tools Needed:

ST-149 326-B

4-5. Changing Drive Roll And Wire Inlet Guide

3 5 1 Securing Screw
2 2 Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without touch-
ing. Tighten screw.
3 Anti-Wear Guide
1 Install guide as shown.
4 Drive Roll

Tools Needed: Install correct drive roll for wire size

and type.
5/64 in 5 Drive Roll Securing Nut
7/16 in Turn nut one click to secure drive
roll.
4
ST-150 227-C

4-6. Aligning Drive Rolls And Wire Guide

Y Turn Off power.
View is from top of drive rolls look-
ing down with pressure assembly
open.
Correct Incorrect
4 1 Drive Roll Securing Nut
3
2 Drive Roll
2
1 3 Wire Guide
4 Welding Wire
5 5 Drive Gear
Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Close pressure roll assembly.
Close door.

Tools Needed:

Ref. ST-800 412-A

4-7. Unicable Repair

To repair or replace unicable, order Unicable Clamp Kit, Part Number 172 018.

OM-1308 Page 13
4-8. Cleaning Or Replacing Gun Liner

Tools Needed:
Y Disconnect gun first.

3/8 in

Head tube

Remove nozzle, contact tip,

adapter, and wire outlet guide.

Wire Outlet Guide

3/8 in

Remove liner.

Lay gun cable out straight

before installing new liner.

Blow out gun casing.

To Reassemble Gun:
Insert new liner.
Install and tighten wire outlet guide.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.

Ref. ST-800 797-A

OM-1308 Page 14
4-9. Replacing Switch And/Or Head Tube

Y Disconnect gun first.

3 Slide handle.

1 Remove handle 2 Remove switch housing. Note: If installing new

locking nut. switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.

4 Secure head 5 Remove shock wash- 6 Loosen jam nut. Remove

tube in vice. ers from front and from vice and turn head
rear of head tube. tube out by hand.

Do not disturb cable connection between

cable connector and connector nut.

7 Install both existing shock washers 8 Place head tube in vice and tighten
to new head tube and hand-tighten to within 1/8 in (3.2 mm) spacing be-
head tube into connector cable. tween connector cable and body.

9 Remove from vice. Reposition

handle and install switch housing.
Secure with handle locking nut.

Tools Needed:

3/4 in
Ref. ST-800 795-A

OM-1308 Page 15
4-10. Troubleshooting

Trouble Remedy

No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-11).

Replace building line fuse or reset circuit breaker if open (see Section 2-11).

Reset circuit breaker CB1 (see Section 4-2).

Secure gun trigger connections (see Section 2-5).

Check and replace Power switch if necessary.

Have Factory Authorized Service Agent check all board connections and main control board.

No weld output; wire feeds. Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 2-2).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 4-4).

An overload condition occurred. Release gun trigger (see Section 4-3).

Have Factory Authorized Service Agent check main control board and main rectifier.

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-11).

Check input voltage jumper links and correct position if necessary (see Section 2-9).

Have Factory Authorized Service Agent check main control board.

Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.
NOTE: Fan only runs when cooling
is necessary.

Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1).

Place Low Range/Full Range switch in correct position (see Section 3-1).

Change to correct size drive rolls (see Section 4-5).

Readjust drive roll pressure (see Section 2-12).

Replace inlet guide, contact tip, and/or liner if necessary (see Sections 4-4, and 4-8).

Check position of input jumper links (see Section 2-9).

Have Factory Authorized Service Agent check main control board.

No wire feed. Reset circuit breaker CB1 (see Section 4-2).

Turn Wire Speed control to higher setting (see Section 3-1).

Clear obstruction in gun contact tip or liner (see Sections 4-4 and 4-8).

Readjust drive roll pressure (see Section 2-12).

Change to correct size drive rolls (see Section 4-5).

Rethread welding wire (see Section 2-12).

Check gun trigger and leads. Repair or replace gun if necessary.

Have Factory Authorized Service Agent check main control board.

Poor weld bead, or welding Check polarity setting for type of welding wire being used (see Section 2-6).
wire is noodle welding.

OM-1308 Page 16
SECTION 5 ELECTRICAL DIAGRAM

SC-175 883-A

Figure 5-1. Circuit Diagram

OM-1308 Page 17
 SECTION 6 PARTS LIST

. Hardware is common and

14

15

16
not available unless listed.

18
13

17

19
12

7
11

8
Fig 6-5

20
10

8
5

6
7

21
Fig 6-2

22
23
3

Fig 6-3
24
2

Fig 6-6
25

ST-801 717

Figure 6-1. Main Assembly

OM1308 Page 18
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-1. Main Assembly

. . . 1 . . . . . . . . . . . 148 597 . . . COUPLER, rod threaded .312-18 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . 146 168 . . . PANEL, center enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . PLG7 . . 083 526 . . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . Fig 6-2 . . . BAFFLE, center w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . T1 . . . 174 553 . . . TRANSFORMER, pwr main (200/230/460) (consisting of) . . . . . . . . . . . . . . . 1
. . . 5 . . . . T1 . . . 174 554 . . . TRANSFORMER, pwr main (230/460/575) (consisting of) . . . . . . . . . . . . . . . 1
. . . 5 . . . . T1 . . . 174 552 . . . TRANSFORMER, pwr main (220/380/415) (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . TP3 . . . 121 497 . . . . THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . 150 387 . . . BAFFLE, air transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . 602 250 . . . WASHER, flat stl SAE .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . 186 758 . . . WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . Z1 . . . 143 892 . . . STABILIZER, (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . Z1 . . . 150 385 . . . STABILIZER, (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . Fig 6-5 . . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 146 165 . . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 089 899 . . . LATCH, slide flush mtg hole 1.000 wide x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . +146 167 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 146 991 . . . LABEL, weld parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . 134 464 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . +170 513 . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 117 860 . . . BLANK, snap-in nyl .187mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . PLG20 . 144 086 . . . CORD SET, pwr 250V 8-10ga 3/c 600V 12ft (200/230V) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 039 778 . . . RECEPTACLE, str 2P3W 50A 250V (200/230V only) . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 144 085 . . . CORD SET, pwr 8-10ga 3/c 600V 12ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 146 161 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . 052 692 . . . AXLE, running gear (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 121 614 . . . . RING, retaining ext .750 shaft x .085grv depth . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . SR1 . . . 173 713 . . . RECTIFIER, SCR main (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 166 667 . . . . CLAMP, spring thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 173 784 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . C3,4 . . 031 689 . . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . 143 818 . . . . THYRISTOR, SCR 325A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . TP1 . . . 154 243 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 171 405 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 143 852 . . . . FOOT, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . TP2 . . . 154 244 . . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 173 714 . . . . CLAMP, thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 602 213 . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . 008 999 . . . CASTER, plstc swvl 4 in dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . 601 871 . . . NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . Fig 6-3 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . 169 596 . . . GUN, 12ft .030-.035 wire (Fig 6-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 182 137 . . . REGULATOR/FLOWMETER, 10-50 CFH Argon/CO2 . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 144 108 . . . HOSE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 130 750 . . . CLAMP, ground 350A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 600 318 . . . CABLE, weld cop strd No. 3 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-1308 Page 19
. Hardware is common and
not available unless listed.

1
2
3
4
5
6
7
8
9
7
6
10 11
34
33
Fig 6-4

35
32

12 13

14

31

15

30
16

25 18
26
19
24 20

17

29 27
21
28
23 22
ST-148 325-C

Figure 6-2. Baffle, Center w/Components

OM1308 Page 20
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 4)

. . . 1 . . . . . . . . . . . 058 427 . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . 085 980 . . . NUT, stl hex full .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . 605 941 . . . WASHER, flat stl .640 ID x 1.000 OD x 14ga thk . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . 057 543 . . . SPRING, cprsn .845 OD x .091 wire x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 057 971 . . . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . 010 191 . . . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . 058 628 . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . 057 745 . . . SPRING, cprsn 2.430 OD x .090 wire x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . 058 428 . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . 177 307 . . . REEL, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 174 813 . . . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 186 998 . . . CAPACITOR KIT,(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 082 902 . . . . STRIP, mtg center capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . 185 643 . . . . STRIP, mtg capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . C5 . . . 184 584 . . . . CAPACITOR, elctlt 15000uf 45VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . 083 147 . . . . GROMMET, scr No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . 187 752 . . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . CR1 . . . 006 393 . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . VR1 . . . 149 542 . . . VARISTOR, 75 joule 350VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . TE1 . . . 143 911 . . . TERMINAL ASSEMBLY, pri 1ph triple voltage (consisting of) . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . 010 913 . . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 19 . . . . . . . . . . . 038 887 . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 20 . . . . . . . . . . . 083 426 . . . . TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 601 835 . . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 22 . . . . . . . . . . . 038 618 . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . 010 199 . . . TUBING, stl .275 ID x .048 wall x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . PC1 . . . 184 316 . . . CIRCUIT CARD, control main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3 . . 115 094 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4 . . 131 052 . . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG5 . . 131 056 . . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . 115 092 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . R1 . . . 119 998 . . . RESISTOR, WW fxd 300W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . 1T . . . 129 524 . . . TERMINAL, frict male .250 x .032 3 pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . C7,8 . . 128 750 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . POS . . 039 047 . . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . NEG . . 039 046 . . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . 071 971 . . . COVER, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . CB1 . . . 123 745 . . . CIRCUIT BREAKER, man reset 1P 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . +144 933 . . . DOOR, access chgov . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . 021 469 . . . LABEL, danger high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . Fig 6-4 . . . WIRE DRIVE & GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-1308 Page 21
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-3. Panel, Front w/Components (Fig 6-1 Item

24)
... 1 . . . . . . . . . . . . . 175 840 . . CONTROL PANEL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . R4 . . . . . 157 366 . . . . RESISTOR, MF .5W 1.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . S2 . . . . . 148 638 . . . . SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 097 924 . . . . KNOB, pointer 1.625dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, indicator upper (order by model and serial number) . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 148 586 . . . . PANEL, front control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . R2,3 . . . . 035 897 . . . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . . . . . . . . . . . . 143 974 . . HANDLE, running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . C9 . . . . . 146 158 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . C10 . . . . 175 719 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . RC1 . . . . 048 282 . . RECEPTACLE w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . S1 . . . . . 128 755 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 174 814 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, indicator lower (order by model and serial number) . . . . . . . . . . . 1
... 14 . . . . PL1 . . . . 157 958 . . LIGHT, ind white lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 057 357 . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . 2
... 16 . . . . . . . . . . . . . 144 127 . . COVER, opening module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. Hardware is common and 7

not available unless listed.
1 6
8
5
4
2 3

16 10

11

15
14 12
13 ST-801 716

Figure 6-3. Panel, Front w/Components

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM1308 Page 22
 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 35)

. . . 1 . . . . . . . . . . . 602 009 . . . SCREW, .250-20 x 1.25 soc hd gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . 172 075 . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . 166 072 . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . 010 224 . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 182 788 . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . 085 242 . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . 085 244 . . . WASHER, cupped stl .328 ID x .812 OD x .125 lip . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 010 231 . . . SPRING, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . 085 243 . . . KNOB, adj tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . 166 071 . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 079 634 . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 151 828 . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . 173 616 . . . COVER, right angle motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PM . . . 173 435 . . . MOTOR, gear 24VDC 122RPM 20:1 ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . 079 633 . . . FITTING, hose brs barbed M 3/16tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 601 966 . . . SCREW, .37516 x 1.25hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 17 . . . . . . . . . . . 145 237 . . . STOP, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . 604 538 . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 124 778 . . . KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . 173 619 . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 174 609 . . . SCREW, M 4.7 x 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . 174 610 . . . SCREW, M 61.0 x 20 soc hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . . . . . . . . 173 620 . . . BUSHING, motor mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . 045 233 . . . GUIDE, anti-wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. Hardware is common and

not available unless listed. 13 14
9

See Table 6-1 For

Drive Roll & Wire Guide Kits. 8 10
11 12
7

6
5
4
3
2

23

22 15
16
21
17

20

19 18 ST-148 529-C

Figure 6-4. Wire Drive And Gears

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1308 Page 23
 Table 6-1. Drive Roll And Wire Guide Kits

Note Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination
with U-Grooved).

Wire Diameter Drive Roll Inlet

Kit No. Wire Guide
Fraction Decimal Metric Part No. Type
.023/.025 in. .023/.025 in. 0.6 mm 087 131 087 130 V-Grooved 056 192
.030 in. .030 in. 0.8 mm 079 594 053 695 V-Grooved 056 192

.035 in. .035 in. 0.9 mm 079 595 053 700 V-Grooved 056 192
.045 in. .045 in. 1.2 mm 079 596 053 697 V-Grooved 056 193
Ref. S-0026-B/7-91

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 6-5. Panel, Rear w/Components (Fig 6-1 Item 10)

... 1 . . . . . . . . . . . 134 834 . . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ft
... 2 . . . . . . . . . . . 149 332 . . . CLAMP, hose .405-.485clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . GS1 . . . 125 785 . . . VALVE, 24VAC 2 way custom port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . 143 810 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . 169 654 . . . BRACKET, support tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . 602 387 . . . CHAIN, weldless 2/0 x 27.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . 605 227 . . . NUT, nyl hex jam .750NPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . 044 426 . . . CONNECTOR, clamp cable .690/1.070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . 010 493 . . . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . 148 242 . . . WINDTUNNEL, 9 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . FM1 . . . 148 808 . . . MOTOR, fan 230V 1550RPM .312dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . 148 809 . . . BLADE, fan 9 in 5wg 34deg .309 bore CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . 049 399 . . . NUT, speed push-on-type .312 stud .625 OD x .456 ID . . . . . . . . . . . . . . . . . . 1
5
. Hardware is common and
not available unless listed. 4
6

3
2
1

10

13
11
12 ST-148 327-C

Figure 6-5. Panel, Rear w/Components

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM1308 Page 24
 Item Part
No. No. Description Quantity

Figure 6-6. M-25 Gun (Fig 6-1 Item 25)

... 1 . . . 169 724 . . NOZZLE, slip type .500 orf .125 recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 169 725 . . NOZZLE, slip type .625 orf .125 recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 169 726 . . NOZZLE, slip type .625 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 169 727 . . NOZZLE, slip type .625 orf .125 stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 176 238 . . NOZZLE, spot flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 176 240 . . NOZZLE, spot inside corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 . . . 176 242 . . NOZZLE, spot outside corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . 087 299 . . TIP, contact scr .023 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 . . . 000 067 . . TIP, contact scr .030 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 . . . 000 068 . . TIP, contact scr .035 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 . . . 000 069 . . TIP, contact scr .045 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . 169 728 . . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . 169 729 . . ADAPTER, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . 170 467 . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . 170 468 . . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . 169 730 . . WASHER, shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . 169 731 . . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . 169 738 . . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . . 169 732 . . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . 169 733 . . CONNECTOR, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . 169 734 . . NUT, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . . . 172 018 . . M25 UNICABLE CLAMP KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 14 . . . . . 169 735 . . . . CLIP, compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . 169 742 . . . . TUBE, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . 169 743 . . . . CLAMP, inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . 170 469 . . . . CLAMP, jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . 169 746 . . . . CONNECTOR, switch lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 2 3 4 5 6 7
8 . Hardware is common and
not available unless listed.

10

11
12
14
15 24
26
16 13* 25

17 22
23

19

27

18 20 18 21
9
10
11
12
17 *Includes Item 18
19
20 ST-800 792

Figure 6-6. M-25 Gun

OM-1308 Page 25
 Item Part
No. No. Description Quantity

Figure 6-6. M-25 Gun (Fig 6-1 Item 25) (Continued)

... 19 . . . . . 169 737 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 20 . . . . . 169 741 . . STRAIN RELIEF, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 21 . . . . . 180 433 . . CABLE, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . 173 521 . . CONNECTOR, feeder (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . 079 974 . . . . O-RING, .500 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 24 . . . 172 257 . . KIT, liner monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . 172 258 . . KIT, liner monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . 172 259 . . KIT, liner monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . . . 079 975 . . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . 169 723 . . GUIDE, outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . 169 739 . . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM1308 Page 26
 Effective January 1, 1997
(Equipment with a serial number preface of KH or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, Torches
warrants to its original retail purchaser that new Miller * Remote Controls
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is * Accessory Kits
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN * Replacement Parts (No labor)
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
* Spoolmate 185
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS. Millers True Blue Limited Warranty shall not apply to:
Within the warranty periods listed below, Miller will repair or 1. Items furnished by Miller, but manufactured by others,
replace any warranted parts or components that fail due to such as engines or trade accessories. These items are
such defects in material or workmanship. Miller must be covered by the manufacturers warranty, if any.
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the 2. Consumable components; such as contact tips, cutting
warranty claim procedures to be followed. nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty 3. Equipment that has been modified by any party other
time periods. All warranty time periods start on the date that than Miller, or equipment that has been improperly
the equipment was delivered to the original retail purchaser, installed, improperly operated or misused based upon
or one year after the equipment is sent to a North American industry standards, or equipment which has not had
distributor or eighteen months after the equipment is sent to reasonable and necessary maintenance, or equipment
an International distributor. which has been used for operation outside of the
specifications for the equipment.
1. 5 Years Parts 3 Years Labor
* Original main power rectifiers MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Inverters (input and output rectifiers only) PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
2. 3 Years Parts and Labor
* Transformer/Rectifier Power Sources In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
* Plasma Arc Cutting Power Sources (2) replacement; or, where authorized in writing by Miller in
* Semi-Automatic and Automatic Wire Feeders appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
* Inverter Power Supplies
payment of or credit for the purchase price (less reasonable
Warranty Questions? * Intellitig depreciation based upon actual use) upon return of the
* Robots goods at customers risk and expense. Millers option of
Call * Engine Driven Welding Generators
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
1-800-4-A-MILLER (NOTE: Engines are warranted separately by the determined by Miller. Therefore no compensation or
engine manufacturer.)
for your local reimbursement for transportation costs of any kind will be
allowed.
3. 1 Year Parts and Labor
Miller distributor. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Motor Driven Guns (w/exception of Spoolmate 185)
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Process Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
* Positioners and Controllers FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Automatic Motion Devices PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Orbital Weld Heads ANY OTHER LEGAL THEORY.
* IHPS Power Sources ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* Water Coolant Systems AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* HF Units REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Grids OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Spot Welders PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* SDX Transformers MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Miller Cyclomatic Equipment EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
* Running Gear/Trailers AND DISCLAIMED BY MILLER.
* Plasma Cutting Torches (except APT, ZIPCUT & Some states in the U.S.A. do not allow limitations of how long
PLAZCUT Models) an implied warranty lasts, or the exclusion of incidental,
* Deutz Engines (outside North America) indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
* Field Options provides specific legal rights, and other rights may be
(NOTE: Field options are covered under True Blue available, but may vary from state to state.
for the remaining warranty period of the product they
are installed in, or for a minimum of one year In Canada, legislation in some provinces provides for certain
whichever is greater.) additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
4. 6 Months Batteries limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
5. 90 Days Parts and Labor rights may be available, but may vary from province to
* MIG Guns/TIG Torches province.
 Owners Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Resources Available
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables

To locate distributor nearest you call Options and Accessories

1-800-4-A-Miller.
Personal Safety Equipment
Service and Repair Miller Electric Mfg. Co.
An Illinois Tool Works Company
Replacement Parts 1635 West Spencer Street
Appleton, WI 54914 USA
Training (Schools, Videos, Books) International HeadquartersUSA
Phone: 920-734-9821
Owners Manuals USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts) European Headquarters
United Kingdom
Circuit Diagrams Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553
Welding Process Handbooks

Contact the Delivering Carrier File a claim for loss or damage during ship-
for: ment.

For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.

PRINTED IN USA 1997 Miller Electric Mfg. Co.