Miller Electric Welder OM 1102 User Manual

OM-1102  
113 214A  
July 1995  
Processes  
Multiprocess Welding  
Description  
Semiautomatic Welding Platform  
Swingpak 12 & 16  
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TABLE OF CONTENTS  
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2
SECTION 3 – INSTALLATION OR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-1. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2
2
2
SECTION 4 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
WARRANTY  
4
 
 
SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS  
1-1.  
GENERAL INFORMATION AND SAFETY  
1-2.  
SAFETY ALERT SYMBOL AND SIGNAL  
WORDS  
A. General  
The following safety alert symbol and signal words are  
used throughout this manual to call attention to and  
identify different levels of hazard and special instruc-  
tions.  
Information presented in this manual and on various la-  
bels, tags, and plates on the unit pertains to equipment  
design, installation, operation, maintenance, and  
troubleshooting which should be read, understood, and  
followed for the safe and effective use of this equipment.  
This safety alert symbol is used with the signal  
words WARNING and CAUTION to call atten-  
tion to the safety statements.  
WARNING statements identify procedures or  
practices which must be followed to avoid seri-  
ous personal injury or loss of life.  
B. Safety  
The installation, operation, maintenance, and trouble-  
shooting of arc welding equipment requires practices  
and procedures which ensure personal safety and the  
safety of others. Therefore, this equipment is to be in-  
stalled, operated, and maintained only by qualified per-  
sons in accordance with this manual and all safety pre-  
cautions in the welding power source Owners Manual.  
CAUTION statements identify procedures or  
practices which must be followed to avoid minor  
personal injury or damage to this equipment.  
IMPORTANT statements identify special instructions  
necessary for the most efficient operation of this equip-  
ment.  
SECTION 2 SPECIFICATIONS  
Gas Cylinder Support Bracket Located  
Here (SWINGPAK-12 Models Only)  
Coolant System  
(Mounted Onto  
SWINGPAK  
Locker)  
Flux  
Tank  
*50-7/8 in.  
(1292 mm)  
Swingpak-12  
Welding  
Power  
Source  
C
F
Boom  
Support  
Base  
E
B
L
Inches  
Millimeters  
A
D
A
B
C
D
E
F
28  
30  
711  
762  
787  
831  
940  
991  
368  
415  
508  
314  
611  
Resistance  
Grid  
(Mounted Onto  
SWINGPAK  
Locker)  
31  
32-3/4  
37  
39  
K
G
H
J
14-1/2  
16-3/4  
20  
G
H
J
K
L
12-3/8  
24-1/16  
**65 in. (1651 mm)  
Swingpak-12  
S-0458-A  
FRONT  
*66-7/8 in. (1699 mm) Swingpak-16  
**79 in. (2007 mm) Swingpak-16  
Figure 2-1. Overall Dimensions, Mounting Hole Layout, And Component Locations  
OM-1102 Page 1  
 
2-1.  
DESCRIPTION  
Additional space is available on the base for mounting  
customer supplied accessories.  
The SWINGPAK-12 and SWINGPAK-16 provide a di-  
rect mounting facility for several welding power sources  
(refer to welding power source Owners Manual for base  
mounting hole layout), SWINGARC wire feeder or CB  
boom, RADIATOR 1A or RADIATOR 2A coolant sys-  
tem, MPG-395B resistance grid, AFT-100 flux tank, and  
shielding gas cylinder. If equipment other than that listed  
is to be used, mounting hole locations may have to be  
modified to accommodate equipment. A SWINGPAK  
locker and brackets for mounting a disconnect switch to  
the SWINGARC post support are also supplied.  
Table 2-1. Specifications  
Weight  
Net  
Ship  
412 lbs.  
(187 kg)  
418 lbs.  
(190 kg)  
SWINGPAK-12  
SWINGPAK-16  
504 lbs.  
(229 kg)  
510 lbs.  
(231 kg)  
SECTION 3 INSTALLATION OR RELOCATION  
WARNING: ELECTRIC SHOCK can kill.  
IMPROPER LIFTING OR INSTALLING OF  
EQUIPMENT can cause personal injury and  
equipment damage.  
Do not touch live electrical parts.  
Disconnect equipment input power conduc-  
tors from deenergized supply line BEFORE  
moving unit.  
Use equipment of adequate capacity to lift  
components.  
Use bolts and fasteners of adequate capacity  
to assemble and install unit.  
3-1.  
LOCATION  
IMPORTANT: Refer to Figures 2-1 and 4-1 during as-  
sembly as necessary.  
When installing this unit, be sure to allow room for the  
boom to swing horizontally in the desired arc, and to piv-  
ot upward to the desired angle. The location should al-  
low room to remove panels of associated equipment for  
installation, inspection, maintenance, and repair proce-  
dures. Consider the input power requirements as well as  
coolant (water) needs of optional equipment when  
choosing a location.  
Mounting hardware is packed in locker for shipping pur-  
poses. Remove hardware kit from locker and proceed  
as follows:  
1. Install boom support base onto SWINGPAK base  
using supplied 1/2-13 x 1-1/2 inch cap screws  
(Item 23, Figure 4-1) and associated hardware  
(see Figure 2-1 for mounting location).  
The service life and efficiency of this unit and associated  
equipment will be reduced if they are subjected to high  
levels of dust, dirt, moisture, corrosive vapors, and ex-  
treme heat.  
2. Locate appropriate mounting holes on SWING-  
PAK base for welding power source, and install  
power source onto SWINGPAK base using  
supplied 3/8-16 x 1-1/4 inch cap screws (Item 20,  
Figure 4-1).  
Mounting holes are provided in the SWINGPAK base for  
installing equipment.  
3. Install boom into boom support base following  
procedure outlined in appropriate Owners Manu-  
al.  
3-2.  
INSTALLATION (Figures 2-1 And 4-1)  
4. If applicable, install AFT-100 flux tank onto  
SWINGPAK base using supplied 5/16-18 x 1 inch  
cap screws (Item 13, Figure 4-1) and associated  
hardware.  
WARNING: OVERTURNING BASE can result  
in serious injury and equipment damage.  
Mount the welding power source on SWING-  
PAK base before mounting SWINGARC wire  
feeder into SWINGARC support base.  
5. Install SWINGPAK locker onto SWINGPAK base  
using supplied 1/4-20 x 3/4 inch self-threading  
screws (item 16, Figure 4-1).  
Do not install or operate on an incline.  
Do not lift the SWINGPAK base with a fork lift  
from the sides unless the lift forks extend far  
enough under the base to ensure against tip-  
ping.  
6. If applicable, install coolant system mounting  
brackets onto SWINGPAK locker using supplied  
1/4-20 x 1inch cap screws (Item 7, Figure 4-1).  
OM-1102 Page 2  
 
IMPORTANT: If cooling system has mounting holes in  
base, do not install mounting brackets onto SWINGPAK  
locker. Instead, install coolant system directly onto lock-  
er using supplied hardware.  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Be sure input power is disconnected and  
welding power source is shut down before  
making connections to disconnect switch.  
7. If applicable, install grid onto SWINGPAK locker  
using supplied 1/4-20 x 1 inch cap screws (Item 7,  
Figure 4-1) and associated hardware.  
11. Install disconnect switch onto boom support, and  
secure using supplied disconnect switch mount-  
ing clamps (Item 2, Figure 4-1) and 3/8-16 nuts  
(Item 5) and associated hardware.  
8. If applicable, install gas cylinder support bracket  
onto SWINGPAK locker using supplied 5/16-18 x  
3/4 inch self-threading screws (item 12, Figure  
4-1).  
9. Install cylinder support bracket to SWINGPAK  
locker using supplied 1/4-20 x 1 inch cap screws  
and associated hardware. Secure gas cylinder in  
bracket using supplied cylinder chain.  
12. Make electrical input connections from welding  
power source to disconnect switch according to  
welding power source Owners Manual.  
10. If applicable, install disconnect switch mounting  
brackets onto disconnect switch (customer must  
supply mounting hardware).  
13. To make electrical connections from line discon-  
nect switch to source of input power, consult local  
electric utility or certified electrician.  
OM-1102 Page 3  
 
SECTION 4 PARTS LIST  
. Hardware is common and  
not available unless listed.  
OM-1102 Page 4  
 
Quantity  
Model  
Item  
No.  
Part  
No.  
Description  
Figure 4-1. Complete Assembly  
12  
16  
. . 1 . . . 086 752 . . BRACKET, mtg disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2  
. . 2 . . . 086 739 . . CLAMP, mtg disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2  
. . 3 . . . 010 910 . . WASHER, flat SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8  
. . 4 . . . 602 213 . . WASHER, lock split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8  
. . 5 . . . 601 872 . . NUT, hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8  
. . 6 . . . 602 207 . . WASHER, lock split .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . 10  
. . 7 . . . 604 631 . . SCREW, hexhd .250-20 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . 10  
. . 8 . . . 099 038 . . BRACKET, mtg coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2  
. . 9 . . . 085 940 . . LOCKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . . . . . . . 085 840 . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3  
. . 10 . . 169 654 . . BRACKET, support tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 11 . . 602 387 . . CHAIN, weldless 2/0 x 27 bright zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 12 . . 602 159 . . SCREW, hexwhd .312-18 x .75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . 13 . . 601 948 . . SCREW, hexhd-pln .312-18 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 14 . . 602 211 . . WASHER, lock split .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 15 . . 087 876 . . BRACKET, support gas bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 16 . . 604 224 . . SCREW, hexwhd .50D .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8  
. . 17 . . 085 939 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 17 . . 086 736 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 18 . . 602 241 . . WASHER, flat stl SAE .250 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 19 . . 602 207 . . WASHER, lock split .250 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 20 . . 601 927 . . SCREW, cap stl hexhd .250-20 x .750 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 18 . . 010 910 . . WASHER, flat SAE .375 (all models except Maxtron 450) . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 19 . . 602 213 . . WASHER, lock split .375 (all models except Maxtron 450) . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 20 . . 604 657 . . SCREW, hexhd-pln .375-16 x 1.250 (all models except Maxtron 450) . . . . . . . . . . 4 . . . 4  
. . 21 . . 602 246 . . WASHER, flat .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 22 . . 602 216 . . WASHER, lock split .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
. . 23 . . 604 467 . . SCREW, hexhd-pln .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4  
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-1102 Page 5  
 
Notes  
 
Effective January 1, 2000  
(Equipment with a serial number preface of LAor newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
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.  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185 & Spoolmate 250  
Canvas Covers  
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.  
Your distributor also gives  
you ...  
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.  
Service  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
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.  
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.  
Support  
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.  
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.  
1. 5 Years Parts 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
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.  
2. 3 Years Parts and Labor  
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
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.  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year Parts and Labor  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
185 & Spoolmate 250)  
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.  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources  
Water Coolant Systems  
HF Units  
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  
Grids  
Maxstar 140  
PROVISION,  
MIGHT  
ARISE  
BY  
IMPLICATION,  
Spot Welders  
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.  
Load Banks  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
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.  
*
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.)  
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.  
4. 6 Months Batteries  
5. 90 Days Parts  
*
*
MIG Guns/TIG Torches  
Induction Heating Coils and Blankets  
miller_warr 7/00  
 
Owners Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
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  
2000 Miller Electric Mfg. Co. 6/00  
 

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