OM-1324

204 408A

November 2001

Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source And

Wire Feeder

Millermatic
135/175
And M-10 Gun
R

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you dont have time to do it any other way.
Thats why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.

TABLE OF CONTENTS

WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)

The following terms are

used interchangeably
throughout this manual:
MIG=GMAW

OM-1324

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Work Cable Routing Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Selecting A Location And Connecting Input Power For 115 VAC Model . . . . . . . . . . . . . . . . .
3-8. Selecting A Location And Connecting Input Power For 230 VAC Model . . . . . . . . . . . . . . . .
3-9. Electrical Service Guide For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld Parameter Chart For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Parameter Chart For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Drive Motor Protection And Tip Saver/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Troubleshooting Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Troubleshooting Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Troubleshooting Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Troubleshooting Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-12. Troubleshooting Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-13. Troubleshooting Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-14. Troubleshooting Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-15. Troubleshooting Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

1
1
1
3
3
4
5
5
5
7
8
8
9
9
10
11
12
12
12
12
13
13
14
15
16
17
17
18
19
19
20
22
24
24
24
24
25
25
26
27
28
29
31
31
32
33
34
35
35
35
36
36
37
37
37
38
38
38
39
40

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_4/98

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.

. Means Note; not safety related.

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
to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

D Wear a safety harness if working above floor level.

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.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
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
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.

D Keep your head out of the fumes. Do not breathe the fumes.

D Always verify the supply ground 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.
D When making input connections, attach proper grounding conductor first double-check connections.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not drape cables over your body.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

OM-1324 Page 1

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.

MAGNETIC FIELDS can affect pacemakers.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
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.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.

OM-1324 Page 2

D Pacemaker wearers keep away.

D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

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

combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards
closed and securely in place.

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 Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.

D
D

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.

D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.

D
D

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.

D
D

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-4. 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 Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection 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
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, 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.

OM-1324 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:

OM-1324 Page 4

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT

UTILISATION
som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdure
prsente des risques de danger ! Ceux-ci sont identifis
par des symboles adjacents aux directives.
Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN
MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connatre les mesures prendre pour
viter tout danger.

1-2. Dangers relatifs au soudage larc

Y Les symboles prsents ci-aprs sont utiliss tout au long du
prsent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnes afin dviter tout danger. Les
consignes de scurit prsentes ci-aprs ne font que rsumer
linformation contenue dans les normes de scurit numres
la section 1-4. Veuillez lire et respecter toutes ces normes de
scurit.
Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies.
Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.

D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-lechamp les pices endommages. Entretenir lappareil conformment
ce manuel.
D Porter un harnais de scurit quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal
avec la pice souder ou la table de travail, le plus prs possible de la
soudure.
D

Isoler la pince de masse quand pas mis la pice pour viter le contact
avec tout objet mtallique.

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peut
provoquer une lectrocution ou des blessures graves.
Llectrode et le circuit de soudage sont sous tension
ds que lappareil est sur ON. Le circuit dentre et les
circuits internes de lappareil sont galement sous
tension ce moment-l. En soudage semi-automatique ou automatique,
le fil, le dvidoir, le logement des galets dentranement et les pices
mtalliques en contact avec le fil de soudage sont sous tension. Des
matriels mal installs ou mal mis la terre prsentent un danger.

Il y a DU COURANT CONTINU IMPORTANT dans les

convertisseurs aprs la suppression de lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique, et dcharger les condensateurs dalimentation selon les instructions
indiques dans la partie entretien avant de toucher les pices.

D Ne jamais toucher les pices lectriques sous tension.

D Porter des gants et des vtements de protection secs ne comportant
pas de trous.
D Sisoler de la pice et de la terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empcher le contact physique ventuel avec la pice ou la terre.
D
D
D

Ne pas se servir de source lectrique courant lectrique dans les zones

humides, dans les endroits confins ou l o on risque de tomber.
Se servir dune source lectrique courant lectrique UNIQUEMENT si le
procd de soudage le demande.
Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
scurit).
D Installer et mettre la terre correctement cet appareil conformment
son manuel dutilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la
borne de terre du sectionneur ou que la fiche du cordon est raccorde
une prise correctement mise la terre.
D En effectuant les raccordements dentre fixer dabord le conducteur
de mise la terre appropri et contre-vrifier les connexions.
D Vrifier frquemment le cordon dalimentation pour voir sil nest pas
endommag ou dnud remplacer le cordon immdiatement sil est
endommag un cble dnud peut provoquer une lectrocution.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss.
D Ne pas enrouler les cbles autour du corps.
D Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct.
D Ne pas toucher llectrode quand on est en contact avec la pice, la
terre ou une lectrode provenant dune autre machine.

LES FUMES ET LES GAZ peuvent

tre dangereux.
Le soudage gnre des fumes et des gaz. Leur
inhalation peut tre dangereux pour votre sant.

D
D
D
D

D Eloigner votre tte des fumes. Ne pas respirer

les fumes.
A lintrieur, ventiler la zone et/ou utiliser un chappement au niveau
de larc pour lvacuation des fumes et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur alimentation dair homologu.
Lire les spcifications de scurit des matriaux (MSDSs) et les
instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs.
Travailler dans un espace ferm seulement sil est bien ventil ou en
portant un respirateur alimentation dair. Demander toujours un
surveillant dment form de se tenir proximit. Des fumes et des
gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger.
Ne pas souder dans des endroits situs proximit doprations de
dgraissage, de nettoyage ou de pulvrisation. La chaleur et les
rayons de larc peuvent ragir en prsence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des mtaux munis dun revtement, tels que lacier
galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien
ventil, et si ncessaire, en portant un respirateur alimentation
dair. Les revtements et tous les mtaux renfermant ces lments
peuvent dgager des fumes toxiques en cas de soudage.

OM-1324 Page 5

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et
sur la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brlures dans les yeux et sur la peau. Des tincelles sont projetes
pendant le soudage.

D Porter un casque de soudage muni dun cran de filtre appropri pour

protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).
D Porter des protections approuvs pour les oreilles si le niveau sondre est
trop lev.

D Utiliser des crans ou des barrires pour protger des tiers de lclair
et de lblouissement; demander aux autres personnes de ne pas regarder larc.
D Porter des vtements de protection constitu dans une matire durable, rsistant au feu (cuir ou laine) et une protection des pieds.

LE SOUDAGE peut provoquer un

incendie ou une explosion.
Le soudage effectu sur des conteneurs ferms tels
que des rservoirs, tambours ou des conduites peut
provoquer leur clatement. Des tincelles peuvent tre
projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peut provoquer des
incendies et des brlures. Le contact accidentel de llectrode avec des
objets mtalliques peut provoquer des tincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vrifier
et sassurer que lendroit ne prsente pas de danger.
D Se protger et dautres personnes de la projection dtincelles et de
mtal chaud.
D Ne pas souder dans un endroit l o des tincelles peuvent tomber sur
des substances inflammables.
D Dplacer toutes les substances inflammables une distance de 10,7
m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus.
D Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.
D Le soudage effectu sur un plafond, plancher, paroi ou sparation
peut dclencher un incendie de lautre ct.
D Ne pas effectuer le soudage sur des conteneurs ferms tels que des
rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de
scurit).
D Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par
des chemins inconnus ventuels en provoquant des risques dlectrocution et dincendie.
D Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact.
D Porter des vtements de protection dpourvus dhuile tels que des
gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTES

peuvent blesser les yeux.
D Le soudage, lcaillement, le passage de la pice
la brosse en fil de fer, et le meulage gnrent
des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier.
D

Porter des lunettes de scurit avec crans latraux ou un cran facial.

OM-1324 Page 6

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou

mme la mort.
D

Fermer lalimentation du gaz protecteur en cas de

non utilisation.
Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

DES PICES CHAUDES peuvent provoquer des brlures graves.

D Ne pas toucher des parties chaudes mains nues
D Prvoir une priode de refroidissement avant
dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D
D

Porteurs de stimulateur cardiaque, restez distance.

Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher
des oprations de soudage larc, de gougeage ou
de soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecter
loue.
D

Porter des protections approuvs pour les oreilles si

le niveau sondre est trop lev.

Si des BOUTEILLES sont endommages, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procd de soudage, les
manipuler avec prcaution.
D Protger les bouteilles de gaz comprim dune chaleur excessive,
des chocs mcaniques, du laitier, des flammes ouvertes, des tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de
se renverser.
D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques.
D Ne jamais placer une torche de soudage sur une bouteille gaz.
D Une lectrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurise risque dexplosion.
D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,
tuyaux et raccords convenables pour cette application spcifique;
les maintenir ainsi que les lments associs en bon tat.
D Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publications P-1 CGA numres dans les normes de scurit.

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance
Risque DINCENDIE OU
DEXPLOSION.

DES ORGANES MOBILES peuvent

provoquer des blessures.

D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces infllammables.

D Rester lcart des organes mobiles comme le

ventilateur.
D Maintenir ferms et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.

D Ne pas installer lappareil proximit de produits inflammables

D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionn et protg avant de mettre
lappareil en service.

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer

des interfrences.

LA CHUTE DE LAPPAREIL peut

blesser.
D Utiliser lanneau de levage uniquement pour soulever lappareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin dune capacit approprie pour
soulever lappareil.
D En utilisant des fourches de levage pour dplacer lunit, sassurer
que les fourches sont suffisamment longues pour dpasser du ct
oppos de lappareil.

LEMPLOI EXCESSIF peut

SURCHAUFFER LQUIPEMENT.

D
D
D
D
D

D Prvoir une priode de refroidissement, respecter le cycle opratoire nominal.

D Rduire le courant ou le cycle opratoire avant de
recommancer le soudage.

LE SOUDAGE LARC risque de

provoquer des interfrences.

D Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pices.
D Utiliser des pochettes et des botes antistatiques
pour stocker, dplacer ou expdier des cartes de
circuits imprimes.

DES ORGANES MOBILES peuvent

provoquer des blessures.
D Ne pas sapprocher des organes mobiles.
D Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gachette avant den avoir
reu linstruction.
D Ne pas diriger le pistolet vers soi, dautres personnes ou toute pice mcanique en engageant le fil
de soudage.

D Le rayonnement haute frequence peut provoquer

des interfrences avec les quipements de radionavigation et de communication, les services
de scurit et les ordinateurs.
Demander seulement des personnes qualifies familiarises
avec des quipements lectroniques de faire fonctionner linstallation.
Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences rsultant de linstallation.
Si le FCC signale des interfrences, arrter immdiatement lappareil.
Effectuer rgulirement le contrle et lentretien de linstallation.
Maintenir soigneusement ferms les portes et les panneaux des
sources de haute frquence, maintenir les clateurs une distance
correcte et utiliser une terre et et un blindage pour rduire les interfrences ventuelles.

D
D
D
D
D

D Lnergie lectromagntique risque de provoquer

des interfrences pour lquipement lectronique
sensible tel que les ordinateurs et lquipement
command par ordinateur tel que les robots.
Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement.
Pour rduire la possibilit dinterfrence, maintenir les cbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller souder une distance de 100 mtres de tout quipement
lectronique sensible.
Veiller ce que ce poste de soudage soit pos et mis la terre
conformment ce mode demploi.
En cas dinterfrences aprs avoir pris les mesures prcdentes, il
incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez distance.
D Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

OM-1324 Page 7

1-4. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Rgles de scurit en soudage, coupage et procds connexes, norme
CSA W117.2, de lAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et sur les effets, pour lorganisme,
des champs magntiques basse frquence

Afin de rduire les champs lectromagntiques dans lenvironnement

de travail, respecter les consignes suivantes :
1

Le courant de soudage, pendant son passage dans les cbles de soudage, causera des champs lectromagntiques. Il y a eu et il y a encore
un certain souci propos de tels champs. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de
recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu: Laccumulation de preuves, suivant le
jugement du comit, na pas dmontr que lexposition aux champs
magntiques et champs lectriques haute frquence reprsente un
risque la sant humaine. Toutefois, des tudes sont toujours en cours
et les preuves continuent tre examines. En attendant que les conclusions finales de la recherche soient tablies, il vous serait
souhaitable de rduire votre exposition aux champs lectromagntiques pendant le soudage ou le coupage.

OM-1324 Page 8

2
3
4
5

Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.
Mettre tous les cbles du ct oppos de loprateur.
Ne pas courber pas et ne pas entourer pas les cbles autour de
votre corps.
Garder le poste de soudage et les cbles le plus loin possible de
vous.
Relier la pince de masse le plus prs possible de la zone de
soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous tes dclar apte par votre docteur, il est
alors recommand de respecter les consignes cidessus.

SECTION 2 SPECIFICATIONS
2-1. Specifications
A. 115 VAC Model
Rated Welding
Output

Maximum
Open-Circuit
Voltage DC

Amperage Range

KVA

KW

Weight
W/ Gun

Overall
Dimensions
Length: 17-1/2 in
(444 mm)

90 A @ 18
Volts DC, 20%
Duty Cycle
30 135

20

2.88

2.40

15*

2.20*

1.77*

28

63 A @ 21
Volts DC, 20%
Duty Cycle*

60 lb
(27 kg)

Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)

Solid
Wire Type
And Dia

Amperes Input at
Rated Load Output 115 V, 60 Hz,
Single-Phase

Stainless

.023 - .035 in
(0.6 - 0.9
mm)

.023 - .030 in
(0.6 - 0.8
mm)

Flux Cored

Wire Feed Speed Range

.030 - .045 in
(0.8 - 1.1 mm)

170 850 IPM (4.3 21.6 m/min) At No Load

75 750 IPM (1.9 19.1 m/min) Feeding Wire

* CSA Rating

B. 230 VAC Model

Rated Welding
Output

Amperage
Range

Maximum OpenCircuit Voltage

DC

Amperes Input at
Rated Load Output
230 V, 50/60 Hz,
Single-Phase

KVA

KW

Weight
W/ Gun

Overall
Dimensions
Length: 17-1/2 in
(444 mm)

130 A @ 20 Volts
DC, 30% Duty Cycle
At 60 Hz Input

30 175

30

19.5

4.60

3.75

73 lb
(33.0 kg)

Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)

Wire Type
And Dia

Solid/
Stainless

Flux Cored

.023 .035 in
(0.6 0.9 mm)

.030 .045 in
(0.8 1.2 mm)

Wire Feed Speed Range

150 900 IPM (3.8 23.0 m/min) At No Load
75 850 IPM (1.9 21.6 m/min) Feeding Wire

OM-1324 Page 9

2-2. Duty Cycle And Overheating

140

Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.

120

Output Amperes

A. 115 VAC
Model

100

If unit overheats, thermostat(s)

opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

RatedOutput

80

Y Exceeding duty cycle can

damage unit or gun and void
warranty.

60
40
20
0

10

20

30

40

50

60

70

80

90

100

Duty Cycle %
20% duty cycle at 90 amps

2 Minutes Welding

B. 230 VAC
Model

8 Minutes Resting

200
180

Output Amperes

160
140
120
100
80
60
40
20
0
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Duty Cycle %
30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz

3 Minutes Welding

7 Minutes Resting

Overheating

A or V

15

OR
Reduce Duty Cycle

Minutes
duty1 4/95 203 771 / 203 796

OM-1324 Page 10

2-3. Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.

A. 115 VAC Model

30

25

VOLTAGE

20

Voltage Control @ 0
Voltage Control @ 1
Voltage Control @ 2
Voltage Control @ 3
Voltage Control @ 4
Voltage Control @ 5
Voltage Control @ 6
Voltage Control @ 7
Voltage Control @ 8
Voltage Control @ 9
Voltage Control @ 10

15

10

0
0.0

10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100. 110. 120. 130.

AMPERAGE

B. 230 VAC Model

35

30

VOLTAGE

25

20
Voltage Control @ 0
Voltage Control @ 1
Voltage Control @ 2
Voltage Control @ 3
Voltage Control @ 4
Voltage Control @ 5
Voltage Control @ 6
Voltage Control @ 7
Voltage Control @ 8
Voltage Control @ 9
Voltage Control @ 10

15

10

0
0

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

AMPERAGE

ssb1.1 10/91 203 772 / 203 797

OM-1324 Page 11

SECTION 3 INSTALLATION
3-1. Installing Welding Gun
1
2
3

Drive Assembly
Gun Securing Knob
Gun End

Loosen knob. Insert gun end

through opening until it bottoms
against drive assembly. Tighten
knob.
4

Gun Trigger Plug

Insert into receptacle, and tighten

threaded collar.
3

Close door.

2
Ref. 802 982 / Ref. 801 987

3-2. Installing Work Clamp

1
2
3
4
5

3
1
2

Nut
Work Cable From Unit
Work Clamp
Screw
Work Clamp Tabs

Bend tabs around work cable.

Tools Needed:
4

5
3/8, 7/16 in

802 456

3-3. Work Cable Routing Inside Unit

1
2
2

Work Cable
Output Terminal Block

Insert work cable through opening

in front panel and route along back
of front panel to output terminal
block.
Close door.
1

Ref. 802 982

OM-1324 Page 12

3-4. Process/Polarity Table

Cable Connections
Process

Polarity
Cable To Gun

Cable To Work

GMAW Solid wire with shielding gas

DCEP Reverse polarity

Connect to positive (+) output terminal

Connect to negative () output

terminal

FCAW Self-shielding wire

no shielding gas

DCEN Straight Polarity

Connect to negative ()
output terminal

Connect to positive (+) output

terminal

3-5. Changing Polarity

1

Lead Connections For Direct

Current Electrode Positive
(DCEP)
Lead Connections For Direct
Current Electrode Negative
(DCEN)

Always read and follow wire

manufacturers recommended polarity, and see Section 3-4.

C H A N G IN G P O L A R IT Y
DCEP
Electrode
ElectrodePOSITIVE
Positive
FOR SOLID WIRE
WorkClamp
Lead

Close door.

DCEN
Electrode Negative
Flux Core Wire
WorkClamp
Lead

2
Wire Drive
Lead

Wire Drive
Lead

Ref. 203 501

OM-1324 Page 13

3-6. Installing Gas Supply

Obtain gas cylinder and chain to
running gear, wall, or other stationary support so cylinder cannot fall
and break off valve.

Tools Needed:
5/8, 1-1/8 in

Cap

Cylinder Valve

Remove cap, stand to side of valve,

and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.

Cylinder

Regulator/Flowmeter

Install so face is vertical.

Regulator/Flowmeter Gas
Hose Connection

Welding Power Source Gas

Hose Connection

Connect customer supplied gas

hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.

Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufacturers recommended flow rate.

Argon Gas
1

OR
2
5

CO2 Adapter (Customer Supplied)

O-Ring (Customer Supplied)

Install adapter with O-ring between

regulator/flowmeter and
CO2
cylinder.

3
8

9
CO2 Gas

802 028 / 802 441

OM-1324 Page 14

3-7. Selecting A Location And Connecting Input Power For 115 VAC Model
1
2
2
1

Rating Label
Grounded Receptacle

A 115 volt, 20 ampere individual

branch circuit protected by time-delay fuses or circuit breaker is required.

18 in
(460 mm)

Plug From Unit

Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for
50 up to 200 ft (61 m).
Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.

18 in
(460 mm)
Ref. 802 980

OM-1324 Page 15

3-8. Selecting A Location And Connecting Input Power For 230 VAC Model
1

Rating Label

Supply correct input power.

2
3

Plug
Receptacle

Connect plug to receptacle.

4

18 in (457 mm) of
space for airflow

Line Disconnect Device

See Section 3-9.

Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.

L1

L2
Y Always connect
grounding
conductor first.
= GND/PE

1
2

L1

L2

230 VAC, 1

Y Do not move or operate unit

where it could tip.

ssb2.2* 1/94 802 980 / Ref. 802 443 / Ref. 802 085

OM-1324 Page 16

3-9. Electrical Service Guide For 230 VAC Model

Input Voltage

230

Input Amperes At Rated Output

20

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

20

Min Input Conductor Size In AWG/Kcmil

14

Max Recommended Input Conductor Length In Feet (Meters)

66 (20)

Min Grounding Conductor Size In AWG/Kcmil

12

Reference: 1996 National Electrical Code (NEC)

S-0092-J

3-10. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in (102 mm) Wire Spool

When a slight force is needed

to turn spool, tension is set.

Installing 8 in (203 mm) Wire Spool

Adapter used with

8 in (203 mm)
spool only.

Retaining ring used

with 8 in (203 mm)
spool only.

When a slight force is needed

to turn spool, tension is set.

Tools Needed:
1/2 in

802 971 / 803 012 / 803 013

OM-1324 Page 17

3-11. Threading Welding Wire

1
2
3
4
5
6

Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Gun Conduit Cable

Lay gun cable out straight.

4
6

Tools Needed:

. Hold wire tightly to keep it

from unraveling.

4 in
(102 mm)

6 in
(150 mm)
Open pressure assembly.

Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

. Use pressure indicator

Tighten

scale to set a desired

drive roll pressure.

1
2
3
4

Pressure
Indicator
Scale

INPUT
POWER

Close and tighten pressure

assembly, and let go of wire.

Remove gun nozzle and contact tip.

Turn power on.

Tighten

WOOD
Press gun trigger until wire comes
out of gun.

Reinstall contact tip and nozzle.

1
2
3
4

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.
Cut off wire. Close door.
Ref. 802 444 / Ref. 205 837

OM-1324 Page 18

SECTION 4 OPERATION
4-1. Controls
1

WIRESPEED

V
VOLTAGE

ON
3

OFF
M A D E IN
M ILL ER EL EC TR IC MF G. CO. A PP LE TO N , W I

TRIGGER

OVERTEMP

POWER

1 Wire Speed Control

Turn control clockwise to increase wire
feed speed. (see weld parameter chart in
welding power source or Sections 4-2 and
4-3, as applicable).

2 Voltage Control
Turn control clockwise to increase voltage
(see weld parameter chart in welding
power source or Sections 4-2 and 4-3, as
applicable).

Power Switch

Over Temperature Light

Gun Trigger Receptacle

Ref. 203 498

OM-1324 Page 19

4-2. Weld Parameter Chart For 115 VAC Model

Selecting Wire, Gas and Control Settings

N o te :

1 . S ett ing s ar e ap p r o x im at e. A d j u s t as r eq u ir ed .
2 . M ea n s n o t r ec o m m en d ed .

W hat M a te ria l
You a re W elding
S te e l

S t a in le s s
S te e l

OM-1324 Page 20

Suggeste d

Sugge ste d

W ire Type s,

Shielding Gases

Pola rity

( Flow Ra te of 2 030 cfh )

S o lid W ire
(o r H a rd )
ER70S 6
(D C E P )

C 25 G a s M ixtu re
75% Ar / 25% C O 2
(A r / C O 2 p ro d u c e s le ss
sp a tte r b e tte r o ve ra ll
a p p e a ra n c e )

. 0 2 4 (0 . 6 m m )

S o lid W ire
(o r H a rd )
ER70S 6
(D C E P )

100% CO 2

. 0 2 4 (0 . 6 m m )

F lu x C o re
E71T11
(D C E N )

N o S h ie ld in g G a s
re q u ire d . G o o d fo r w in d y
o r o u td o o r a p p lic a tio n s.
M a y re q u ire a n o v e rs ize d
tip fo r im p ro v e d fe e d ib ility.

. 0 3 0 (0 . 8 m m )

S ta in le ss
S te e l
(D C E P )

T ri M ix
9 0 % H e / 7 .5 % A r / 2 .5 % C O 2

. 0 3 0 (0 . 8 m m )

W ire Size
( Dia m eters )

. 0 3 0 (0 . 8 m m )
. 0 3 5 (0 . 9 m m )

. 0 3 0 (0 . 8 m m )
. 0 3 5 (0 . 9 m m )

. 0 3 5 (0 . 9 m m )
. 0 4 5 (1 . 2 m m )

S e le ct V o lta g e a n d W ire S p e e d B a se d o n T h i ckn e ss o f M e ta l B e i n g W e l d e d

N u m b er o n left o f s lash

N u m b er o n rig h t o f s las h

is V o ltag e K n o b S ettin g .

is W ir e S p eed K n o b S ettin g .

3 /1 6

1 /8

1 6 ga.

2 0 ga .

2 4 ga .

( 4.8 m m )

( 3.2 m m )

( 1.6 m m )

( 0.9 m m )

( 0. 8 m m)

7 / 70

3 / 55

2.5 / 40

2 / 30

8 / 75

3.5 / 55

2.5 / 40

2 / 35

8 / 75

4 / 45

2 / 25

9 / 55

4 / 55

3 / 40

9 / 70

3.5 / 60

2 / 40

9 / 60

6 / 50

3 / 40

7 / 80

5 / 60

3 / 40

8 / 70

5 / 60

3 / 40

7.5 / 65

6 / 60

9 / 70

5 / 45

4.5 / 40

203 501

OM-1324 Page 21

4-3. Weld Parameter Chart For 230 VAC Model

Selecting Wire, Gas and Control Settings

N o te:

1 . S et t ing s a r e a p p r o x im a t e . A d j u s t a s r e q u ir e d .
2 . M ea n s n o t r e c o m m e n d ed .

S u g g e s te d

S u g g e s te d

W h a t M a te ri a l

W i re S i ze
W i re T y p e s,

Y o u a re W e l d in g
P o l a ri ty
S te e l

S t a in le s s
S te e l

OM-1324 Page 22

S h i e l d i n g G a se s
( F l o w R a te o f 2 0 3 0 cfh )

( D i a m e te rs )

S o lid W ire
(o r H a rd )
E R 70S 6
(D C E P )

C 25 G a s M ix tu re
75% Ar / 25% C O 2
(A r / C O 2 p ro d u c e s le s s
s p a tte r b e tte r o v e ra ll
a p p e a ra n c e )

. 0 2 4 (0 . 6 m m )

S o lid W ire
(o r H a rd )
E R 70S 6
(D C E P )

100% C O 2

. 0 2 4 (0 . 6 m m )

F lu x C o re
E 71T11
(D C E N )

N o S h ie ld in g G a s
re q u ire d . G o o d fo r w in d y
o r o u td o o r a p p lic a tio n s.
M a y re q u ire a n o ve rs iz e d
tip fo r im p ro v e d fe e d ib ility .

. 0 3 0 (0 . 8 m m )

S ta in le s s
S te e l
(D C E P )

T ri M ix
9 0 % H e / 7 .5 % A r / 2 .5 % C O 2

. 0 3 0 (0 . 8 m m )

. 0 3 0 (0 . 8 m m )
. 0 3 5 (0 . 9 m m )

. 0 3 0 (0 . 8 m m )
. 0 3 5 (0 . 9 m m )

. 0 3 5 (0 . 9 m m )
. 0 4 5 (1 . 2 m m )

. 0 3 5 (0 . 9 m m )

S e le c t V o lta g e a n d W i re S p e e d B a s e d o n T h i c kn e s s o f M e ta l B e i n g W e l d e d
N u m b er o n left o f s las h

N u m b er o n r ig h t o f s las h

is V o ltag e K n o b S ettin g .

is W ir e S p eed K n o b S ettin g .

1 /4

3 /1 6

1 /8

1 6 ga .

2 0 ga .

2 4 ga .

(6. 4 m m )

(4. 8 m m )

(3. 2 m m )

(1. 6 m m )

(0. 9 m m )

(0. 8 m m )

8 / 90

8 / 90

4 / 75

3 / 70

2 / 45

1 / 50

8 / 80

5 / 75

4 / 70

2.5 / 55

1.5 / 60

1.5 / 45

8 / 75

5 / 75

3.5 / 75

3 / 70

2 / 60

8 / 85

4 / 70

2 / 70

1.5 / 60

9.5 / 70

4.5 / 70

3.5 / 60

2.5 / 55

1.5 / 45

6.5 / 70

5.5 / 70

4 / 70

3 / 55

1.5 / 40

8 / 80

6 / 80

5 / 50

3 / 40

8 / 70

6 / 75

4 / 70

3 / 45

5 / 70

5 / 60

4 / 50

3.5 / 40

7 / 75

4 / 65

3.5 / 45

2.5 / 30

7 / 75

5 / 70

4.5 / 40

203 501

OM-1324 Page 23

SECTION 5 MAINTENANCE &TROUBLESHOOTING

5-1. 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 heavy
service, clean
monthly.

Or

5-2. Overload Protection

1

Circuit Breaker CB1

CB1 protects unit from overload. If

CB1 opens, unit shuts down.
1

Reset breaker.

802 441

5-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun
trigger and wait until protection circuit resets allowing drive motor to feed wire again.
B. Tip Saver/Short Circuit Protection
The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact
tip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation,
release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and
remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.
OM-1324 Page 24

5-4. Changing Drive Roll Or Wire Inlet Guide

1

Inlet Wire Guide

Remove guide by pressing on

barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2
1

Stamped .024

Retaining Pin

To secure drive roll, locate open slot

and push drive roll completely over
retaining pin, then rotate drive roll
20 (1/4 turn) to closed slot.

.030/.035 Groove

Drive Roll

The drive roll consists of two different sized grooves. The stamped
markings on the end surface of the
drive roll refers to the groove on the
opposite side of the drive roll. The
groove closest to the motor shaft is
the proper groove to thread (see
Section 3-11).

.024 Groove

Stamped .030/.035

802 984

5-5. Replacing Gun Contact Tip

Y Turn Off power before
replacing contact tip.
1
2

Nozzle
Contact Tip

Cut off welding wire at contact tip.

Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.

1
Tools Needed:

Ref. 802 399-A

OM-1324 Page 25

5-6. Cleaning Or Replacing Gun Liner

Tools Needed:
Y Disconnect gun from unit.
8 mm / 10 mm

Head Tube

Remove nozzle, contact tip,

adapter, gas diffuser, and wire
outlet guide.
8 mm

10 mm

Remove liner.

Lay gun cable out straight

before installing new liner.

To Reassemble Gun:
Install and tighten new liner.

Blow out gun casing.

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-802 399-A

OM-1324 Page 26

5-7. Replacing Switch And/Or Head Tube

Y Turn Off welding power source
/wire feeder and disconnect gun.

Remove handle
locking nut.

3
2

Slide handle.

Remove switch housing. Install new switch and

connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube,
continue to end of figure.

4 Secure head
tube in vice.

Loosen jam nut.

Remove from vice
and turn head tube
out by hand.

Hand-tighten head tube into cable connector.

Place head tube in vice and tighten until

nuts are tight.

Remove from vice. Reposition handle and install

switch housing. Secure with handle locking nut.

Tools Needed:

19 mm

Ref. ST-800 795-C

OM-1324 Page 27

5-8. Troubleshooting Table

Trouble

Remedy

No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-7).
does not run.
Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 4-1).
Reset welding power source circuit breaker if open.
No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
motor continues to run.
unit has cooled (see Section 2-2).
Secure gun trigger leads (see Section 3-1).
No weld output; wire feeds.

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 5-5).
Check for proper polarity connections (see Section 3-5).
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Low weld output.

Connect unit to proper input voltage or check for low line voltage.
Place voltage switch in desired position (see Section 4-1).

Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding.
Adjust drive roll pressure (see Section 3-11).
Change to proper drive roll groove (see Section 5-4).
Readjust hub tension (see Section 3-10).
Replace contact tip if blocked (see Section 5-5). Oversized tip may be required for some wires.
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-4 or Section 5-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 5-4).
Secure gun trigger leads or repair leads (see Section 3-1).
Check and clear any restrictions at drive assembly and liner (see Section 3-11 or Section 5-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Have nearest Factory Authorized Service Agent check drive motor.

OM-1324 Page 28

SECTION 6 ELECTRICAL DIAGRAM

203 765

Figure 6-1. Circuit Diagram For 115 VAC Model

OM-1324 Page 29

203 794

Figure 6-2. Circuit Diagram For 230 VAC Model

OM-1324 Page 30

SECTION 7 MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections

Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Regulator/
Flowmeter

Wire Feeder/
Power Source

Shielding Gas
Gun
Gas

Work Clamp

Workpiece

light mig 5/967 / Ref. 802 982

OM-1324 Page 31

7-2. Typical MIG Process Control Settings

NOTE

These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.

Material thickness determines weld

parameters.

1/8 or
.125 in

Convert Material
Thickness to
Amperage (A)
(.001 in = 1 ampere)
.125 in = 125 A

.035 in

Wire Size

Amperage Range

.023 in

30 90 A

.030 in
.035 in

40 145 A
50 180 A

Select Wire Size

Wire
Size

Recommendation

Wire Speed
(Approx.)

Select Wire Speed

(Amperage)

.023 in
.030 in
.035 in

3.5 in per ampere

2 in per ampere
1.6 in per ampere

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm
1.6 x 125 A = 200 ipm

125 A based on 1/8 in

material thickness
ipm = inch per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Select Voltage

Set voltage midway between high/low voltage.

Wire speed (amperage) controls weld penetration

(wire speed = burn-off rate)

Voltage controls height and width of

weld bead.

Ref. 802 980

OM-1324 Page 32

7-3. Holding And Positioning Welding Gun

NOTE

Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.

2
3
4
5

Hold Gun and Control Gun

Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
1/4 to 1/2 in (6 To 13 mm)
Cradle Gun and Rest Hand on
Workpiece

0-15
90

90

End View Of Work Angle

Side View Of Gun Angle

GROOVE WELDS

0-15

45
45

End View Of Work Angle

Side View Of Gun Angle

FILLET WELDS

S-0421-A

OM-1324 Page 33

7-4. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.

10

Push

Perpendicular

10

Drag

GUN ANGLES AND WELD BEAD PROFILES

Short

Normal

Long

ELECTRODE EXTENSIONS (STICKOUT)

Short

Normal

Long

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Slow

Normal
GUN TRAVEL SPEED

OM-1324 Page 34

Fast

S-0634

7-5. Gun Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.

1
1

2
3

Stringer Bead Steady

Movement Along Seam
Weave Bead Side To Side
Movement Along Seam
Weave Patterns

Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

7-6. Poor Weld Bead Characteristics

1

1
2
3
4
5

Large Spatter Deposits

Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration

5
S-0053-A

7-7. Good Weld Bead Characteristics

1
2
3

Fine Spatter
Uniform Bead
Moderate Crater During
Welding

Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals
being welded.
4
5
2

No Overlap
Good Penetration into Base
Metal

5
S-0052-B

OM-1324 Page 35

7-8. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles that
cool to solid form near weld bead.

S-0636

Possible Causes

Corrective Actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage range.

Electrode extension (stickout) too long.

Use shorter electrode extension (stickout).

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.

7-9. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas pockets
in weld metal.

S-0635

Possible Causes
Insufficient shielding gas at welding arc.

Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas.

Use welding grade shielding gas; change to different gas.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.

OM-1324 Page 36

7-10. Troubleshooting Excessive Penetration

Excessive Penetration weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639

Possible Causes
Excessive heat input.

Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.

7-11. Troubleshooting Lack Of Penetration

Lack Of Penetration shallow
fusion between weld metal and
base metal.
Lack of Penetration

Good Penetration
S-0638

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.

Improper weld technique.

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.

7-12. Troubleshooting Incomplete Fusion

Incomplete Fusion failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

S-0637

Possible Causes

Corrective Actions

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.

Insufficient heat input.

Select higher voltage range and/or adjust wire feed speed.

Improper welding technique.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.
OM-1324 Page 37

7-13. Troubleshooting Burn-Through

Burn-Through weld metal melting completely through base metal
resulting in holes where no metal remains.

S-0640

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

Wrong polarity.

Configure polarity as shown in Section 3-5. Always read and follow wire manufacturers
recommended polarity, and see Section 3-4.

7-14. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not cover
joint formed by base metal.

S-0641

Possible Causes

Corrective Actions

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand.

Support hand on solid surface or use two hands.

7-15. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642

Possible Causes
Excessive heat input.

Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.

OM-1324 Page 38

7-16. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas

Spray Arc Steel

Short Circuiting Steel

Short Circuiting
Stainless Steel

Argon

Short Circuiting
Aluminum
All Positions

Argon + 25% CO2

Flat & Horizontal1 Fillet

All Positions

CO2

Flat & Horizontal1 Fillet

All Positions

Tri-Mix3

Globular Transfer

Single Pass Welding Only

90% HE + 7-1/2% AR + 2-1/2% CO2

All Positions2

All Positions

OM-1324 Page 39

24

22

20

12
13

10

26

42

25

30

. Hardware is common and

31

33

30

35

34

39

38

29

37 36

28

27

11

40

41

14

15

16

23

18

17

32

19

21

SECTION 8 PARTS LIST

not available unless listed.

907 020

Figure 8-1. Main Assembly

OM-1324 Page 40

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Main Assembly

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

1
2
3
4
5
6
7
7
8
9
9
10
11
12
12
13
14
15
16
16
17
18
19
19
20
20
21
22
22
23
23
24
25
26
26
27
28
29
30

. . . . . . . . . . . . . . . . . . 202 581 . . .
. . . . . . . . . . . . . . . . . . 202 582 . . .
. . . . . . . . . . . . . . . . . . 202 583 . . .
. . . . . . . . . . . . . . . . . . 202 584 . . .
. . . . . . . . . . . . . . . . . . 202 411 . . .
. . . . . . . . . . . . . . . . . . 202 412 . . .
. . . . . PC1 . . . . . . . 199 820 . . .
. . . . . PC1 . . . . . . . 202 354 . . .
. . . . . . . . . . . . . . . . . . 134 201 . . .
. . . . . SK1 . . . . . . . . 193 191 . . .
. . . . . SK1 . . . . . . . . 193 316 . . .
. . . . . . . . . . . . . . . . . . 204 215 . . .
. . . . . . . . . . . . . . . . . . 193 194 . . .
. . . . . . C1 . . . . . . . . 193 039 . . .
. . . . . . C1 . . . . . . . . 193 040 . . .
. . . . . . . . . . . . . . . . . . 203 491 . . .
. . . . . CB1 . . . . . . . 210 109 . . .
. . . . . . . . . . . . . . . . . . 111 433 . . .
. . . . . . . . . . . . . . . . . . 147 545 . . .
. . . . . . . . . . . . . . . . . . 152 118 . . .
. . . . . . . . . . . . . . . . . . 195 585 . . .
. . . . . . . . . . . . . . . . . . 605 227 . . .
. . . . . GS1 . . . . . . . 116 996 . . .
. . . . . GS1 . . . . . . . 128 751 . . .
. . . . . . FM . . . . . . . . 196 063 . . .
. . . . . . FM . . . . . . . . 196 064 . . .
. . . . . . . . . . . . . . 409 953-001 . . .
. . . . . . T1 . . . . . . . . 203 445 . . .
. . . . . . T1 . . . . . . . . 203 456 . . .
. . . . . . Z1 . . . . . . . . 203 868 . . .
. . . . . . Z1 . . . . . . . . 203 874 . . .
. . . . . . . . . . . . . . . . . . 196 467 . . .
. . . . . . . . . . . . . . . . . . 196 619 . . .
. . . . . . S1 . . . . . . . . 196 575 . . .
. . . . . . S1 . . . . . . . . 196 574 . . .
. . . . . PL1 . . . . . . . . 202 661 . . .
. . . . . . R1 . . . . . . . . 202 663 . . .
. . . . . . R2 . . . . . . . . 202 662 . . .
. . . . . . . . . . . . . . . . . . 205 882 . . .

BASE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WRAPPER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HINGE, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF support PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER ASSY (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER ASSY (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR (positive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR (negative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 53,000 uf (115 VAC model) . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 100,000 uf (230 VAC model) . . . . . . . . . . . . . . . .
CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, 25 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORD SET (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORD SET (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, 2 way (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, 2 way (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, fan (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, fan (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STABILIZER, 90A (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . .
STABILIZER, 130A (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, pvc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker SPST (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker DPDT (230 VAC model) . . . . . . . . . . . . . . . . . . . . . .
LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POTENTIOMETER, cp flat 1T .50W 50k . . . . . . . . . . . . . . . . . . . . . . .
POTENTIOMETER, cp flat 1T .25W 50k . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
2
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2

+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-1324 Page 41

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Main Assembly (Continued)

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

31
31
32
33
34
35
36
37
38
39
40
41
42

..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
. . . . . TE1 . . . . . . . .

203 501 . . .
203 765 . . .
204 036 . . .
204 711 . . .
202 725 . . .
058 427 . . .
202 726 . . .
203 072 . . .
202 998 . . .
204 608 . . .
602 211 . . .
203 071 . . .
193 144 . . .

LABEL, weld guide (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, weld guide (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, precautionary static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATCH, slide flush snap lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADAPTER, spool hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
1
1
1
1
1
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-1324 Page 42

203 565

Figure 8-2. Wire Feed Drive Assembly

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-2. Wire Feed Drive Assembly

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

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
. . . . . DM . . . . . . . .
..................
..................
..................
..................

202 500 . . .
203 424 . . .
058 549 . . .
196 895 . . .
090 415 . . .
198 080 . . .
085 242 . . .
203 567 . . .
204 246 . . .
203 301 . . .
189 915 . . .
202 708 . . .
196 009 . . .
203 418 . . .
202 925 . . .
203 667 . . .

HOUSING, plastic drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIN, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUIDE, wire inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUP, spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVER, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROLL, feed .024, .030/.035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
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-1324 Page 43

4
5

6
7

10
11
12

802 388-A

Figure 8-3. M-10 Gun

OM-1324 Page 44

Item
No.

Part
No.

Description

Quantity

Figure 8-3. M-10 Gun

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

1
2
2
2
2
3
4
5
6
7
8
9
10
10
10
11
12

. . . . . 169 715
. . . 087 299
. . . 000 067
. . . 000 068
. . . 000 069
. . . . . 169 716
. . . . . 170 470
. . . . . 169 718
. . . . . 169 738
. . . . . 194 524
. . . . . 180 433
. . . . . 079 974
. . . 194 010
. . . 194 011
. . . 194 012
. . . . . 079 975
. . . . . 196 255

. . NOZZLE, slip type .500 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . TIP, contact scr .023 wire x 1.125
. . TIP, contact scr .030 wire x 1.125
. . TIP, contact scr .035 wire x 1.125
. . TIP, contact scr .045 wire x 1.125
. . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD, trigger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O-RING, .500 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
2
1
1
1
1
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.
Table 8-1. Optional Drive Rolls
For All Feed Head Assemblies
PART NO.

WIRE DIAMETER INCHES (mm)

202 925

.024 (.6) and .030/.035 (.8 and .9)

202 926

.030/.035 (.8 and .9) and .045 (1.2 VK Groove)

Table 8-2. Options

PART NO.

DESCRIPTION

REMARKS

770 187

Running Gear/Cylinder Rack

For One Small Gas Cylinder, 100 lb (45 kg)

194 776

Small Running Gear/Cylinder Rack

For One Small Gas Cylinder, 75 lb (34 kg)

195 605

M-10 Replacement Gun

10 ft length/.030-.035 wire size

NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.

OM-1324 Page 45

Notes

Effective January 1, 2000

(Equipment with a serial number preface of LA or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

LIMITED WARRANTY Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
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, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller 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 a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.

5 Years Parts 3 Years Labor

*
*
2.

3 Years Parts and Labor

*
*
*
*
*
*

3.

Original main power rectifiers

Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)

1 Year Parts and Labor

*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue 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

*
*

MIG Guns/TIG Torches

Induction Heating Coils and Blankets

*
*
*
*
*

APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers

Millers True Blue Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

2.

Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.

3.

Equipment that has been modified by any party other

than Miller, 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.

MILLER 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 Millers option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller 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 customers risk and expense. Millers option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. 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 MILLER 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 MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
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.
miller_warr 7/00

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

For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

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

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Replacement Parts
Training (Schools, Videos, Books)

International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams

European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

Welding Process Handbooks

www.MillerWelds.com

Contact the Delivering Carrier for:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.

PRINTED IN USA

2001 Miller Electric Mfg. Co.

1/01