Miller Electric A1D-4RV Owner`s manual

OM-1580C
134 192C
May 1996
Processes
Automatic Welding
Description
Wire Feeder
A1D-4RV And A1D-4RW
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 don’t have time to do it any other way.
That’s 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 couldn’t 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. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s 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. We’ve
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, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered to
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard.
service information for your particular model
are also provided.
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.
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.
TABLE OF CONTENTS
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 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Overall Dimensions And Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Wire Guides And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Outlet Cable, Weld Cable, And Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Threading And Feeding Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Aligning Drive Rolls And Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Brush Inspection And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
3
3
4
5
5
5
6
6
7
7
8
8
8
8
8
9
10
10
11
12
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. 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 – do not use work clamp or work 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
Owner’s 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
manufacturer’s 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-1580 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-1580 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.
D
OVERUSE can cause OVERHEATING
D
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-1580 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
committee’s 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-1580 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 2 – SPECIFICATIONS
2-1. Specifications
Specification
Description
Type Of Input Power
115 Volts DC
Input Power Cord
12 in (305 mm)
Overall Dimensions
See Section 2-2
Weight
18 lb (7.9 kg)
Wire Feed Speed Range
50 To 780 ipm (1.3 To 19.8 mpm)
Wire Diameter Range
.030 Thru 1/8 in (0.8 Thru 3.2 mm)
2-2. Overall Dimensions And Mounting Hole Layout
Inches
Millimeters
A
12-3/4
324
B
8-7/8
225
C
9-3/8
238
A
A
B
C
C
Inches
Millimeters
A
3.54
90
B
8.27
218
C
3/8 Dia.
4 Holes
9.5 Dia.
4 Holes
B
ST-134 761
OM-1580 Page 5
SECTION 3 – INSTALLATION
3-1. Installing Wire Guides And Drive Rolls
When changing wire size or type,
check drive roll and guide size (see
Table 7-1).
1
Wire Guide Securing Screw
2
Inlet Wire Guide
3
Intermediate Wire Guide
Loosen wire guide screws.
Slide tip as close to drive rolls as
possible without touching. Tighten
screw.
1
4
Drive Gear
5
Pressure Gear
Drive and pressure gears installed
before unit is shipped from factory.
6
Pressure Gear Assembly
Open pressure gear assembly.
6
2
3
7
Drive Roll
8
Gear Securing Bolt
9
Drive Roll Securing Screw
Install correct drive roll for wire size
and type using supplied hardware.
Side View
Close pressure gear assembly.
7
8
5
9
4
3
Tools Needed:
7/16 in
ST-070 887-E
OM-1580 Page 6
3-2. Outlet Cable, Weld Cable, And Gas Connections
6
7
Connect To
Gas Fitting
On Robot
Connect To Positive (+) Weld
Output Terminal On Welding
Power Source For Reverse
Polarity Weld Process Or
Connect To Negative (–) Weld
Output Terminal On Welding
Power Source For Straight
Polarity Weld Process.
1
Outlet Cable Securing Knob
2
Outlet Cable Opening
3
Outlet Cable End
Loosen knob. Insert outlet cable
end into opening. Position as close
as possible to drive rolls without
touching. Tighten knob.
Connect 4-pin plug from outlet cable
to the 4-socket receptacle on the
motor mounting bracket.
4
Weld Cable Terminal
5
Weld Cable
Select and prepare weld cable according to welding power source
Owner’s Manual.
6
Shielding Gas Fitting
7
Gas Hose
Gas fitting is located behind outlet
cable opening.
Connect gas hose from fitting on robot to shielding gas fitting on wire
drive assembly.
1
2
3
4
5
Tools Needed:
9/16 in
Ref. ST-156 544
3-3. Threading And Feeding Welding Wire
Loosen wire from wire spool, cut off
bent wire, and pull 6 in (150 mm) of
wire off spool.
5
5
Wire Inlet Guide
2
Drive Roll
3
Intermediate Wire Guide
4
Gun
Thread wire through inlet guide,
along drive rolls, through intermediate guide and drive rolls, into outlet
cable, and out of the gun. Be sure
wire is in correct groove.
5 Pressure Adjustment Knob
And Arm
4
1
2
1
WOOD
Close pressure roll assembly.
Check drive roll pressure by feeding wire against a wood board or
concrete surface; wire should feed
steadily without slipping.
If pressure adjustment is necessary, tighten pressure knobs.
3
ST-045 282-C / Ref. ST-156 798
OM-1580 Page 7
SECTION 4 – OPERATION
4-1. Safety Equipment
3
2
1
Wear the following while welding:
1
Dry, Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
4-2. Sequence Of Operation
Install &
Connect
Equipment
Thread & Feed
Welding Wire
Put On
Personal Safety
Equipment
Turn On
Shielding Gas
Turn On Robot
Control And Welding
Power Source
Run A
Welding
Program
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Turn Off all power before maintaining.
3 Months
See
Section
7
3-2
3 Months
Tape Or
Replace
Cracked
Weld
Cable
Replace
Unreadable
Labels
––
Clean
And
Tighten
Weld
Terminals
6 Months
Replace
Cracked
Parts
––
OR
––
Cord
OM-1580 Page 8
Gun Cable
During Heavy Service,
Clean Monthly
Clean
Drive
Rolls
3-1
Gas Hose
Blow Out
Or
Vacuum
Unit
5-2. Aligning Drive Rolls And Wire Guides
CAUTION
IMPROPER CLEARANCE between motor gear and drive gears on four-drive roll models can damage
equipment.
•
Maintain 0.003 in (0.076 mm) clearance between motor gear and drive gears.
Gears may wear severely, bind, break, or cause erratic wire feed if proper clearance is not maintained.
Horizontal Alignment
View is from top of drive rolls looking down with pressure assembly
open.
Horizontal Alignment
Correct
Alignment
Incorrect
Alignment
4
3
2
1
Drive Roll Securing Bolt
2
Drive Roll
3
Wire Guide
4
Welding Wire
5
Drive Gear
Turn bolt in or out until drive roll
groove lines up with wire guide.
5
1
Vertical Alignment
6
Housing Bolts
7
Weld Cable Terminal
Loosen bolts and terminal nut(s).
Vertical Alignment
8
Wire Guide
9
Drive Roll
10 Pressure Roll
Slide housing up or down until
groove in drive roll and pressure roll
line up with wire guide.
10
Tighten hardware. Close pressure
roll assembly.
8
8
9
7
Tools Needed:
7/16 in
9/16 in
6
7
S-0629-A / ST-045 282-C / S-0087
OM-1580 Page 9
5-3. Brush Inspection And Replacement
1
Motor
2
Brush Cap
Remove brush cap.
3
Brush
Replace brush if it becomes
chipped or broken, or if less than
1/4 in. (6.4 mm) of brush material is
left. Do not include spring boss as
part of the 1/4 in. measurement.
1
Install brush so that curved surface
on end of brush matches curve of
motor, and secure with cap.
Repeat procedure for other brush.
3
2
1/4 in (6 mm)
Minimum Length
5/8 in (16 mm)
New Length
Tools Needed:
Replace
Damaged Brushes
ST-137 390-C / S-0816
5-4. Troubleshooting
Trouble
Wire feeds erratically.
Remedy
Adjust drive roll pressure by turning pressure adjustment knob(s) 1/4 turn clockwise until wire stops slipping. Check gun contact tip for obstructions.
Check size of drive roll (see Section 3-1).
Replace drive roll if worn (see Section 3-1).
Clean drive roll, and check wire spool hub tension.
Check and secure motor plug connection (see Section 3-2).
Align drive rolls (see Section 5-2).
Wire stops feeding while welding.
Align drive rolls (see Section 5-2).
Replace motor.
Motor runs slowly.
Reduce load.
Check for correct input voltage.
Motor runs at full speed regardless of Have Factory Authorized Service Station/Service Distributor check digital wire drive motor Tachometer
wire speed setting.
board and encoder disc.
Operation Module servo light on, Teach Check and secure servo warning light(s) connection.
Pendant display on, servo warning
light(s) off (A1D-4RV model only).
Replace burned out servo warning light(s).
OM-1580 Page 10
SECTION 6 – ELECTRICAL DIAGRAMS
SA-134 193-B
Figure 6-1. Circuit Diagram For A1D-4RV
ST-174 873-A
Figure 6-2. Circuit Diagram For A1D-4RW
OM-1580 Page 11
OM-1580 Page 12
For Drive Roll & Wire Guide Kits
See Table 7-1
Includes
Item 26
28
32
27 29 30 31
22
25
11
19
12
18
17
10
33
9
34
8
7
2
3
4
5
6
35
48
14
46
37
45
44
38
3
26
36
not available unless listed.
13
47
40 39
14 16 15
43
42 41 40 39 38
ST-134 750-B
SECTION 7 – PARTS LIST
20
Includes
Items 13-16
1
23 24
. Hardware is common and
Figure 7-1. Main Assembly (A1D-4RV Model Illustrated)
21
29
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
A1D-4RV A1D-4RW
Figure 7-1. Main Assembly
. . 1 . . . . . . . . . . . . . 046 779
. . 2 . . . . . . . . . . . . . 602 154
. . 3 . . . . . . . . . . . . . 010 224
. . 4 . . . . . . . . . . . . . 085 242
. . 5 . . . . . . . . . . . . . 085 244
. . 6 . . . . . . . . . . . . . 010 231
. . 7 . . . . . . . . . . . . . 085 243
. . 8 . . . . . . . . . . . . . 166 337
. . 9 . . . . . . . . . . . . . 166 071
. . 10 . . . . . . . . . . . . 079 634
. . 11 . . . . . . . . . . . . 151 828
. . 12 . . . . . . . . . . . . 166 338
. . 13 . . . . . . . . . . . . 144 172
. . 14 . . . . . . . . . . . . 166 072
. . 15 . . . . . . . . . . . . 604 538
. . 16 . . . . . . . . . . . . 079 772
. . 17 . . . . . . . . . . . . 134 177
. . 18 . . . . . . . . . . . . 075 150
. . 19 . . . . . . . . . . . . 010 910
. . 20 . . . . . . . . . . . . 602 213
. . 21 . . . . . . . . . . . . 079 624
. . 22 . . . . . . . . . . . . 134 171
. . 23 . . . . . . . . . . . . 010 116
. . 24 . . . PLG2 . . . 134 860
. . . . . . . . . . . . . . . . . . 134 184
. . 25 . . . . . . . . . . . . 604 571
. . 26 . . . PLG1 . . . 048 282
. . . . . . . . . . . . . . . . . . 079 534
. . 22 . . . . . . . . . . . . 174 496
. . 23 . . . . . . . . . . . . 010 116
. . 24 . . . PLG2 . . . 126 147
. . . . . . . . . . . . . . . . . . 126 084
. . 25 . . . . . . . . . . . . 604 525
. . 26 . . . PLG1 . . . 048 282
. . . . . . . . . . . . . . . . . . 079 534
. . 27 . . . . . . . . . . . . 092 865
. . 28 . . . . . . . . . . . . 172 995
. . 29 . . . . . . . . . . . . 172 807
. . . . . . . . . . . . . . . . . . 153 491
. . . . . . . . . . . . . . . . . . 153 492
. . . . . . . . . . . . . . . . . *153 493
. . 30 . . . PLG3 . . . 134 858
. . . . . . . . . . . . . . . . . . 134 184
. . 31 . . . . . . . . . . . . 173 000
. . 32 . . . . . . . . . . . . 131 203
. . . . . . . . . . . . . . . . . . 114 656
. . 33 . . . . . . . . . . . . 153 631
. . 34 . . . . . . . . . . . . 132 611
. . 35 . . . . . . . . . . . . 134 176
. . 36 . . . PL1,2 . . . 117 160
. . . . . . . . . . . . . . . . . *115 276
. . 37 . . . . . . . . . . . . 010 142
. . 38 . . . . . . . . . . . . 053 842
. . 39 . . . . . . . . . . . . 079 626
. . 40 . . . . . . . . . . . . 605 518
. . 41 . . . . . . . . . . . . 072 010
. . . DRIVE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . SCREW, .250-20 x .500 hexwhd stl slffmg . . . . . . . . . . . . . . . 2 . . . . . . .
. . . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
. . . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
. . . . . WASHER, cupped .328 ID x .812 OD x .125 lip stl . . . . . . . . 2 . . . . . . .
. . . . . SPRING, cprsn .770 OD x .105 wire x 1.225 lg . . . . . . . . . . . 2 . . . . . . .
. . . . . KNOB, adjustment tension 1.250dia x .312-18 thrd . . . . . . . 2 . . . . . . .
. . . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . PIN, cotter hair .042 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . FITTING, brs barbed M 3/16tbg x .250-20 . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . WASHER, flat .344 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . KNOB, T 2.000 bar w/.312-18 stud x 1.500 lg . . . . . . . . . . . . 1 . . . . . . .
. . . INSULATOR, drive assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . WASHER, shldr .406 ID nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . WASHER, flat .406 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . WASHER, lock .380 ID stl split . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
. . . SCREW, .375-16 x 2.250 hexhd stl . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . CABLE, shock sensor & lights (consisting of) . . . . . . . . . . . . . . 1
. . . . . GROMMET, rbr .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . 1
. . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, rect pin 20-16ga . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . CABLE, port No. 18 4/c (order by ft) . . . . . . . . . . . . . . . . . . . 1ft
. . . . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . 4
. . . CABLE, shock sensor (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . GROMMET, rbr .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . CONNECTOR, rect 2 pin 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . CABLE, port No. 18 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . CONNECTOR & SOCKETS (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONNECTOR, circ skt pushin 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . .
. . . KEY, stl .1215/.1230 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . MOTOR, gear (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . MOTOR, gear 1/8hp 115VDC 2000RPM (consisting of) . . . 1 . . . . . . .
. . . . . . KIT, brush replacement (consisting of) . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . . . CAP, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
. . . . . . . BRUSH, carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
. . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . . CONNECTOR, rect pin 20-16ga . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . .
. . . . . CABLE, motor 12 in tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . .
. . . . . CIRCUIT CARD, tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . . . OPTICAL ENCODER, disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . BRACKET, mtg motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . PILOT LAMP, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . BULB, LED red 28V min bayonet . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CLAMP, nyl .312dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . .
. . . GEAR, spur insulated w/bearing . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . .
. . . SCREW, 10-32 x .875 filhd stl lkg . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . .
. . . BOLT, stl tap hexhd .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . .
. . . WASHER, shldr .316 ID nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . .
1
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1ft
1
4
1
1
1
1
2
2
1
6
1
1
3
1
1
1
1
4
15
4
2
OM-1580 Page 13
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
A1D-4RV A1D-4RW
Figure 7-1. Main Assembly
..
..
..
..
..
..
..
42
43
44
45
46
47
48
............
............
............
............
............
............
............
602 241
602 207
044 735
000 418
093 664
601 872
602 243
...
...
...
...
...
...
...
WASHER, flat .281 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock .255 ID stl split . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, .250-28 x 1.750 hexhd stl . . . . . . . . . . . . . . . . . . . . . .
SCREW, .250-20 x .500 hexhd lkg . . . . . . . . . . . . . . . . . . . . . . .
GEAR, spur insulated drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, .375-16 stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat .438 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2
2
1
1
1
1
.......
.......
.......
.......
.......
.......
.......
3
2
2
1
1
1
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1580 Page 14
Table 7-1. Drive Roll & Wire Guide Kits (4 Drive Roll)
NOTE
Fraction
Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).
Wire Diameter
Decimal
.023/.025 in
.023/.025 in
Metric
Kit No.
Drive Roll
Part No.
Type
Wire Guide
Inlet
Intermediate
0.6 mm
087 132
087 130
V-Grooved
056 192
056 206
.030 in
.030 in
0.8 mm
046 780
053 695
V-Grooved
056 192
056 206
.035 in
.035 in
0.9 mm
046 781
053 700
V-Grooved
056 192
056 206
.045 in
.045 in
1.2 mm
046 782
053 697
V-Grooved
056 193
056 207
.052 in
.052 in
1.3 mm
046 783
053 698
V-Grooved
056 193
056 207
1/16 in
.062 in
1.6 mm
046 784
053 699
V-Grooved
056 195
056 209
.035 in
.035 in
0.9 mm
044 750
072 000
U-Grooved
056 192
056 206
.045 in
.045 in
1.2 mm
046 785
053 701
U-Grooved
056 193
056 207
.052 in
.052 in
1.3 mm
046 786
053 702
U-Grooved
056 193
056 207
1/16 in
5/64 in
.062 in
.079 in
1.6 mm
2.0 mm
046 787
046 788
053 706
053 704
U-Grooved
U-Grooved
056 195
056 195
056 209
056 209
3/32 in
.094 in
2.4 mm
046 789
053 703
U-Grooved
056 196
056 210
7/64 in
.110 in
2.8 mm
046 790
053 705
U-Grooved
056 196
056 210
1/8 in
.126 in
3.2 mm
046 791
053 707
U-Grooved
056 197
056 211
.035 in
.035 in
0.9 mm
046 792
132 958
V-Knurled
056 192
056 206
.045 in
.045 in
1.2 mm
046 793
132 957
V-Knurled
056 193
056 207
.052 in
.052 in
1.3 mm
046 794
132 956
V-Knurled
056 193
056 207
1/16 in
.062 in
1.6 mm
046 795
132 955
V-Knurled
056 195
056 209
5/64 in
.079 in
2.0 mm
046 796
132 960
V-Knurled
056 195
056 209
3/32 in
.094 in
2.4 mm
046 797
132 961
V-Knurled
056 196
056 210
7/64 in
.110 in
2.8 mm
046 798
132 962
V-Knurled
056 196
056 210
1/8 in
.126 in
3.2 mm
046 799
132 963
V-Knurled
056 197
056 211
.045 in
.045 in
1.2 mm
083 319
083 489
U-Cogged
056 193
056 207
.052 in
.052 in
1.3 mm
083 320
083 490
U-Cogged
056 193
056 207
1/16 in
.062 in
1.6 mm
046 800
053 708
U-Cogged
056 195
056 209
5/64 in
.079 in
2.0 mm
046 801
053 710
U-Cogged
056 195
056 209
3/32 in
.094 in
2.4 mm
046 802
053 709
U-Cogged
056 196
056 210
7/64 in
.110 in
2.8 mm
046 803
053 711
U-Cogged
056 196
056 210
1/8 in
.126 in
3.2 mm
046 804
053 712
U-Cogged
056 197
056 211
S-0025-D
OM-1580 Page 15
Notes
OM-1580 Page 16
Notes
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
Miller’s 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 manufacturer’s 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 Miller’s 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 customer’s risk and expense. Miller’s 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.
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Owner’s 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 Headquarters–USA
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
manufacturer’s Transportation Department.
PRINTED IN USA
 2000 Miller Electric Mfg. Co.
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