Miller ST 432 User manual

Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Wire Feeder
OM-199 448 October 2000
Effective with serial number: 165 280
ST 432 Wire Feeder
Visit our website at
www.MillerWelds.com OWNER’S MANUAL

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 figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and 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.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You

TABLE OF CONTENTS
SECTION 1 –SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 –DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Rating Label 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols and Definitions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 –OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 –MAINTENANCE & TROUBLESHOOTING 8. . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 –ELECTRICAL DIAGRAM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTON 6 –PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

dec_con_ita 5/97
Declaration of Conformity
“CE”Dichiarazione di Conformità
Manufacturer’s Name:
Nome del Costruttore: Miller Europe S.p.A
Manufacturer’s Address:
Indirizzo Costruttore: Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Declares that this product:
Dichiara che il Prodotto: ST 432 Wire Feeder
Conforms to the following Directives and Standards:
È Conforme alle seguenti Direttive e Norme. Directives
Low Voltage: 73/23/EEC
Direttiva bassa tensione: 73/23/CEE
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC
CompatibilitàElettromagnetica: (EMC) 89/336/CEE, 92/31/CEE
Machinery Directives: 89/392/EEC
Direttiva Macchine: 89/392/CEE
And their amendments 91/368/EEC, 93/C 133/04, 93/68/EEC
Aggiornate dalle direttive 91/368/CEE, 93/C 133/04, 93/68/CEE
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1, 1989
Prescrizioni di sicurezza per apparecchi di saldatura ad arco, Sezione 1: EN 60974-1, 1989
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 - Draft revision)
Apparecchi di saldatura ad arco, Sezione 1: Alimentatori per saldatura: IEC 974-1 (Aprile 1995 - Revisione preliminare)
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: December 1995
Norma sulla compatibilitàelettromagnetica (EMC) dei prodotti per apparecchi di saldatura ad arco:
EN50199, dicembre 1995
Degrees of Protection provided by Enclosures (IP code): IEC 529 : 1989
Grado di protezione fornito dagli involucri (codice IP): IEC 529 : 1989
European Contact: Mr. Luigi Vacchini, Managing Director
In Europa Contattare: MILLER Europe S.P.A.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Telefono: 39(0)2-98290-1
Fax: [phone]

OM-199 448 Page 1
SECTION 1 –SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
MeansWarning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
YMarks 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.
Consultsymbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
YThe 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.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
YDuring operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touchinglive electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electricallylive 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
groundedequipment is a hazard.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
DDo not use AC output in damp areas, if movement is confined, or if
thereis a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DDisconnect 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).
DProperly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground –check and be sure that input
powercord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
DWhenmaking input connections, attach proper grounding conduc-
tor first –double-check connections.
DFrequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged –bare wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or poorly spliced cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
singleweld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
beforetouching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use exhaust at the arc to remove
weldingfumes and gases.
DIf ventilation is poor, use an approved air-supplied respirator.
DRead the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners,and degreasers.
DWork in a confined space only if it is well ventilated, or while
wearingan air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
DDo not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
DDo not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

OM-199 448 Page 2
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.
ARC RAYS can burn eyes and skin.
DWear 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).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash and
glare;warn others not to watch the arc.
DWear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
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.
WELDING can cause fire or explosion.
DProtect yourself and others from flying sparks and hot metal.
DDo not weld where flying sparks can strike flammable material.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
DConnect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknownpaths and causing electric shock and fire hazards.
DDo not use welder to thaw frozen pipes.
DRemove stick electrode from holder or cut off welding wire at
contact tip when not in use.
DWear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
DWelding,chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShut off shielding gas supply when not in use.
DAlways ventilate confined spaces or use
approvedair-supplied respirator.
HOT PARTS can cause severe burns.
DDo not touch hot parts bare handed.
DAllow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
DPacemaker wearers keep away.
DWearers should consult their doctor before
going near arc welding, gouging, or spot
weldingoperations.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
DWear approved ear protection if noise level is
high.
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.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeepcylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder –explosion will result.
DUse only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associatedparts in good condition.
DTurn face away from valve outlet when opening cylinder valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DRead and follow instructions on compressed gas cylinders,
associatedequipment, and CGA publication P-1 listed in Safety
Standards.

OM-199 448 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustiblesurfaces.
DDo not install unit near flammables.
DDo not overload building wiring –be sure power supply system is
properlysized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
supportunit.
DIf using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
weldingwire.
MOVING PARTS can cause injury.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
DHigh-frequency(H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronicequipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
ARC WELDING can cause interference.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DBe sure all equipment in the welding area is
electromagneticallycompatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded
accordingto this manual.
DIf 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
WeldingSociety, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers That Have Held Hazardous Substances, American
WeldingSociety Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite501, 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-199 448 Page 4
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Weldingcurrent, as it flows through welding cables, will cause electro-
magnetic 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 power-
frequency 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
weldingor cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
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 opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemakerwearers consult your doctor first. If cleared by your doctor,
thenfollowing the above procedures is recommended.

OM-199 448 Page 5
SECTION 2 –DEFINITIONS
1 1.1 1.2 1.3
3 3.1 3.2 3.3
4 4.1 +
22.1 2.2
+
+
56
+
2.3
S-178 936
A. Warning!Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation –keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
2-1. Warning Label Definitions
ABC

OM-199448 Page 6
2-2. Rating Label
ST 432 WIRE FEEDER
24
350/60 Hz
IP 23
V
A1
MADE IN ITALY
2-3. Symbols and Definitions
Symbols found on product.
NOTE
On Off Input Output
AAmperes VVolts AlternatingCurrent XDuty Cycle
IP Degree Of
Protection Hz Hertz Circuit Breaker Wire Feed
Jog U1Primary Voltage Gas Metal Arc
Welding (GMAW)
Gun Line Connection
Purge Spot Weld Time Spot Weld Continuous Weld
Burnback Time Preflow Time Postflow Time Read Instructions
U2Load Voltage I1Primary Current I2Rated Current U1Primary Voltage

OM-199 448 Page 7
SECTION 3 –OPERATION
3-1. Control Panel
12T–4T Switch
2 Jog
3 Purge Gas
4 Power ON-OFF
5 Voltage Control
6 Wire Speed Control
7 Circuit Breaker
8 Flowmeter
9 Remote Control Switch
10 Remote Control Receptacle
11 In-Out Cold Torch
12 Torch Connection
13 Digital Voltmeter/mpm
14 Gas In Connector
15 Control Cable Connection
16 Weld Cable Connection
17 In-Out Cooling System
1 2 34 5
6
8
9
10
11
13
12
16
14
15
17
7

OM-199 448 Page 8
SECTION 4 –MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
YDisconnectpower before maintaining.
3 Months
Replace
Unreadable
Labels
CleanAnd
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Weld Cable
14-Pin Cord Gas HoseGun Cable
Replace Cracked Parts
6 Months
Blow Out Or Vacuum Inside,
During Heavy Service, Clean
Monthly
OR
Clean Drive Rolls

OM-199 448 Page 9
4-2. Troubleshooting
Problem Solution
Wiredoes not feed, unit completely inop- Turn Power switch On.
erative. Check 14–pin receptacle connections.
Check input power or the CB
Wire does not feed. Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds erratically. Readjust hub tension and drive roll pressure.
Use correct size drive roll (see Parts List).
Clean or replace dirty or worn drive roll.
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed. Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s Manual.
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.
Wire does not feed until trigger is
pressed but continues to feed after trig-
ger is released.
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas valve rattles loudly and wire feeds
slowly or erratically. Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas does not flow; wire feeds. Check gas valve and flowmeter.

OM-199 448 Page 10
Notes

OM-199 448 Page 11
SECTION 5 – ELECTRICAL DIAGRAM
6
MOTOR P C B
– +
M
PT
Gs
CB
43
21
1
2
3
4
12
3
4
25
23
23
25
23
23 25
28
29
54
22 24 21 13 20
1
2
S1
S6
CR1
CR
S2 RMT
33
PURGE GAS
WIRE SPEED
Cr1
Cr1
RMT STD
P
2
123
26
30 35
27
7
RC
RC
69
3
10
11
13
15
17
S4
CONT.
IMP. 36
S3
JOG
Cr Cr
22
24 STD RMT
32
31
VOLTAGE CONTROL
P
3
MIN SPEED ADJ. 3V
MAX SPEED ADJ. 23.5 V
START
BURN BAK
METERS PCB
RC1
PLG1
G A BCED–H+
cod.956 142 430
12345678910 11121314151617181920
6
6

OM-199448 Page 12
SECTON 6 –PARTS LIST
Figure 6-1. Complete Assembly
43
42
45
44
46
48
47
49
41 40 39
38
37
6
2
1
4
3
7810
9
5
50
11
12
13 14 15
18
20
17
22 23
33
25 26
27
28
29
30
31
32
34
35
36
24
51
19
16
21
6
6
.Hardwareis common and
not available unless listed.
52
53

OM-199 448 Page 13
Item Dia Ref. Code Qty.Dwg Item Dia Ref. Code Qty.Dwg
Basic Basic
1 156018033 1 1
2 156009079 1 1
3 156032064 G.F.1.0.4 1 1
4 156009075 GF.1.0.2 1 1
5 000010191 FU.1.0.6 1 1
6 000058628 FU.1.0.7 1 1
7 656102001 BH.0.0.3 1 1
8 116009041 CV.0.0.2 1 1
9 000058628 FU.1.0.7 1 1
10 000010191 FU.1.0.6 1 1
11 056076216 ZO.0.0.22 1 1
12 PLG1 056076192 PQ.0.2.1 1 1
13 GS 056061042 UV.0.0.7 1 1
14 116118164 XY.0.0.4 1 1
15 117060011 XY.0.1 1 1
16 CR. & CR. 1 000006393 QA.0.0.10 2 2
17 117090004 XY.0.4 1 1
18 00126416 OL.0.0.5 1 1
19 000126415 OL.0.0.4 1 1
20 116121120 XY.0.0.6 1 1
21 CB 000083432 PC.0.0.1 1 1
22 S2 056067169 OM.0.0.6 1 1
23 058016012 ZO.1 1
24 Motor P.C.B. 057064048 OL.0.2 1 1
25 V/MPM 057095012 XY.0.5 1
26 P2 W. SP. 056059182 DC.0.0.9 1 1
27 000097922 BP.2.0.20 2 2
28 P3 V. Contr. 056059182 DC.0.0.9 1 1
29 S1 056067194 OP.0.0.8 1 1
30 S6 056093022 XY.0.0.7 1 1
31 S3 056093022 XY.0.0.7 1 1
32 S4 056067169 OM.0.06 1 1
33 RC 056076180 CV.0.0.5 1 1
34 756005012 FU.1.6.1 1 1
35 Red 0570521026 XE.1.9 1
35 Blue 057052025 XE.1.8 1
36 116118163 XY.0.0.2 1 1
37 M 24Vdc 057010047 XY.0.2 1 1
38 057062006 ZC.4.2 2 2
39 057052019 QF.0.13 1 1
40 058066022 ZC.4 1 1
41 756007010 ZC.4.0.9 1 1
42 556090036 ZC.4.0.8 1 1
43 0,6-0,8 V 156053072 ZC.0.0.13 2 2
43 0,8-1 V 156053077 ZC.0.0.18 2 2
43 1-1,2 V 156053073 ZC.0.0.14 2 2
43 1,2-1,6 V 156053076 ZC.0.0.17 2 2
43 1,2-1,6 K 156053074 ZC.0.0.15 2 2
43 1-1,2 AL 156053075 ZC.0.0.16 2 1
43 1,2-1,6 AL. 156053078 ZC.0.0.19 2 2
43 1,6-2,4 K 156053079 ZC.0.0.20 2 2
43 2,4-3,2 K 156053080 ZC.0.0.21 2 2
44 156017155 ZC.4.2.1 2 2
45 556090035 ZC.4.0.7 1 1
46 156076079 ZC.4.0.6 2 2
47 656064002 ZC.3.0.5 2 2
48 1560322122 ZC.4.0.4 2 2
49 56018002 ZC.4.0.3 2 2
50 151187 PV.0.0.18 1 1
51 11612311 XY.0.0.5 1 1
52 316029670 XY.0.0.3 1 1
53 Red 556049373 XY.0.0.9 1
53 Blu 556049372 XY.0.0.8 1
OPTIONAL
Running gear 028041048 XY.0.8 1 1
Remote
control AV 028040193 FZ.1 1 1
Cable for
remote control 027014925 FZ.0.2 1 1

Notes

Effective January 1, 2000
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITEDWARRANTY –Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Miller
equipmentsold 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
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years —Parts and Labor
* 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.)
3. 1 Year —Parts and Labor
* DS-2 Feeder
* Motor Driven Guns (w/exception of Spoolmate 185
and Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* IHPS 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 and Spoolmate 250
* Canvas covers
Miller’s True BlueLimited Warranty shall not apply to:
1. 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.
2. 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.
3. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
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
limitationor 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
limitationsand 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. milan_warr 7/00

PRINTED IN USA 2000 Miller Electric Mfg. Co. 1/00
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: [phone]
USA & Canada FAX: [phone]
International FAX: [phone]
European Headquarters –
United Kingdom
Phone: [phone]
FAX: [phone]
Miller Europe
Italy
Phone: [phone]
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
Please complete and retain with your personal records.
Owner’s Record