Maxstar® 161 S
With Auto-Line ™
Eff w/Serial No.
MG440092L And Following
For OM-275099 Revision A Thru D
PARTS MANUAL
MG440092L Maxstar 161 S Stick Welder
PM-275099A 2020-09
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding .
Description
Arc Welding Power Source
SECTION 1 – PARTS LIST FOR S MODELS MG440092L AND FOLLOWING
Figure 1-1. Main Assembly
Eff w/Serial No. MG440092L And Following
| Item No. | Dia. Mkgs. | Part No. | Description | |
| Figure 1-1. Main Assembly | ||||
| 1 | 271781 | Insulator, Heat/Sink Wrapper | 1 | |
| 2 | 221497 | Bumper, Polyurethane .500 Od x .140 High Adh Backed | 1 | |
| 3 | 271799 | Pin, Retaining .188 Od x 2.125 Lg | 2 | |
| 4 | 146549 | Rivet, Plastic .122 Hole x .039-.079 Grip Push | 1 | |
| 5 | 208622 | Label, Warn Elect Shock/Explode Parts/Do Not Remove | 1 | |
| 6 | 275817 | Strap, Handle/Shoulder Assy | 1 | |
| 7 | 195666 | Screw, 010-32 x .50 Pan Hd-Torx w/Gndrng StI Pld | 2 | |
| 8 | 277200 | Label, Warning General Precautionary (En/Fr/Sp) | 1 | |
| 9 | 271784 | Wrapper | 1 | |
| 10 | 278902 | Cable, Power 2.0m 14Ga 3c 5-15p (125V/15A) To SDG | 1 | |
| 11 | 278903 | Cable, Power 2.0m 12Ga 3c 5-50p (250V/50A) To SDG | 1 | |
| 12 | RC1 | 274991 | Receptacle, SDG 2.5mm Panel Mount Housing w/Leads | 1 |
| 13 | 277017 | Cover, Receptacle | 1 | |
| 14 | 275055 | Nameplate, Maxstar 161 (Rear) | 1 | |
| 15 | 208558 | Term, Frict 250 x 032 Uninsul Male 10-32 Mtg 45 Deg | 2 | |
| 16 | 208535 | Screw, K50 x 12 Rnd Wshr Hd – Trx SO Pld Delta Pt | 2 | |
| 17 | PC2 | 272651 | Circuit Card Assy, User Interface | 1 |
| 18 | PC1 | 278311 | Circuit Card Assy, Windtunnel w/Cmpnts | 1 |
| 19 | 274398 | Panel, Rear | 1 | |
| 20 | FM | 271789 | Fan, Muffin 24 VDC 92 x 38mm 5400 Rpm | 1 |
| 21 | 206258 | Relay, End 24 VDC SPST30S/24 VDC 4-Pin Flange Mtg | 1 | |
| 22 | 275818 | Tape, Adh Double Sided 3M VHB .045in. x lin. Square | 1 | |
| 23 | 273760 | Windtunnel, Magnetics Assy w/HF | 1 | |
| 24 | 271781 | Base (Order by Model and Serial Number) | 1 | |
| 25 | 208497 | Nut, M5-.8 x 12mm Hex 8.3mm T StI PId Sem Con Washer | 1 | |
| 26 | 274397 | Panel, Front w/HF | 1 | |
| 27 | 208561 | Work Clamp, w/Cable & Connector – 10 Ft | 1 | |
| 28 | 208596 | Holder, Electrode w/Cable & Connector | 1 | |
| 29 | 244862 | Screw, M5-.8 x 12 Soc Hd – Torx St! Pld Sems Piloted | 1 | |
| 30 | NEG | 208612 | Rcpt Assy, Tw Lk Power/Gas Female Neg | 1 |
| 31 | 230052 | Knob, .840 Dia x 6mm Id w/Spring Clip – 4.5 | 1 | |
| 32 | POS | 271791 | Receptacle, Twist Lock Brass Power Female (Pos) | 1 |
| 33 | 273308 | Nameplate, Maxstar 161 | 1 | |
| 34 | 254151 | Nut, M07-.75 10mm Hex 2mm H StI Pld | 1 | |
Notes
MATERIAL THICKNESS REFERENCE CHART
Maxstar ®161 STH
With Auto-Line™
Eff w/Serial No.
MG440092L And Following
For OM-275099 Revision A Thru D
SECTION 2 – PARTS LIST FOR STL MODELS MG440092L AND FOLLOWING
Figure 2-1. Main Assembly
Eff w/Serial No. MG440092L And Following
| Item No. | Dia. Mkgs. | Part No. | Description | |
| Figure 2-1. Main Assembly | ||||
| 1 | 271781 | Insulator, Heat/Sink Wrapper | 1 | |
| 2 | 221497 | Bumper, Polyurethane .500 Od x .140 High Adh Backed | 1 | |
| 3 | 271799 | Pin, Retaining .188 Od x 2.125 Lg | 2 | |
| 4 | 146549 | Rivet, Plastic .122 Hole x .039-.079 Grip Push | 1 | |
| 5 | 208622 | Label, Warn Elect Shock/Explod Parts/Do Not Remove | 1 | |
| 6 | 275817 | Strap, Handle/Shoulder Assy | 1 | |
| 7 | 195666 | Screw, 010-32 x .50 Pan Hd-Torx w/Gndrng Stl Pld | 2 | |
| 8 | 277200 | Label, Warning General Precautionary (En/Fr/Sp) | 1 | |
| 9 | 271784 | Wrapper | 1 | |
| 10 | 278902 | Cable, Power 2.0m 14Ga 3c 5-15p(125V/15A) To SDG | 1 | |
| 11 | 278903 | Cable, Power 2.0m 12Ga 3c 5-50p(250V/50A) To SDG | 1 | |
| 12 | RC1 | 274991 | Receptacle, SDG 2.5mm Panel Mount Housing w/Leads | 1 |
| 13 | 277017 | Cover, Receptacle | 1 | |
| 14 | 275057 | Nameplate, Maxstar 161 (Rear) | 1 | |
| 15 | 208558 | Term, Frict 250 x 032 Uninsul Male 10-32 Mtg 45 Deg | 2 | |
| 16 | 219967 | Valve, 14 VDC 2way .625-18 Thd 2.2mm Orf 90 PSI | 1 | |
| 17 | 271790 | Hose, Poly Clear .170 Id x .250 Od x 11.000in. w/Clamps | 1 | |
| 18 | 208535 | Screw, K50 x 12 Rnd Wshr Hd – Trx St! Pld Delta Pt | 2 | |
| 19 | PC3 | 274565 | Circuit Card Assy, 6 Pin Remote w/Cmpnts | 1 |
| 20 | PC2 | 272651 | Circuit Card Assy, User Interface | 1 |
| 21 | PC1 | 278311 | Circuit Card Assy, Windtunnel w/Cmpnts | 1 |
| 22 | 271783 | Panel, Rear | 1 | |
| 23 | FM | 271789 | Fan, Muffin 24 VDC 92x38mm 5400 Rpm | 1 |
| 24 | 206258 | Relay, Encl 24 VDC SPST308/24 VDC 4-Pin Flange Mtg | 1 | |
| 25 | 275818 | Tape, Adh Double Sided 3M VHB .045in. x lin. Square | 1 | |
| 26 | 273760 | Windtunnel, Magnetics Assy w/HF | 1 | |
| 27 | 271781 | Base (Order by Model and Serial Number) | 1 | |
| 28 | 208497 | Nut, M5-.8 x 12mm Hex 8.3mm T St’ Pld Sem Con Washer | 1 | |
| 29 | 271782 | Panel, Front | 1 | |
| 30 | 208561 | Work Clamp, w/Cable & Connector – 10 Ft | 1 | |
| 31 | 208596 | Holder, Electrode w/Cable & Connector | 1 | |
| 32 | 273483 | Adapter, Torch-Intn1 Style Flow Thru | 1 | |
| 33 | 244862 | Screw, M5-.8 x 12 Soc Hd – Torx St! Pld Sems Piloted | 1 | |
| 34 | 208588 | Nut, .625-27 .81 Hex .14 H Thermoplastic Black | 1 | |
| 35 | NEG | 208612 | Rcpt Assy, Tw Lk Power/Gas Female Neg | 1 |
| 36 | 230052 | Knob, .840 Dia x 6mm Id w/Spring Clip – 4.5 | 1 | |
| 37 | POS | 271791 | Receptacle, Twist Lock Brass Power Female (Pos) | 1 |
| 38 | 208589 | Cover, Dust Receptacle | 1 | |
| 39 | 273312 | Nameplate, Maxstar 161 (Front) | 1 | |
| 40 | 254151 | Nut, M07-.75 10mm Hex 2mm H StI Pld | 1 | |
Notes
Welding Tip:
Securely connect work clamp to a clean area close to the weld joint.
Maxstar®161 STH
With Auto-Line™
Eff w/Serial No.
MG440092L And Following
For OM-275099 Revision A Thru D
SECTION 3 – PARTS LIST FOR STH MODELS MG440092L AND FOLLOWING
| Item No. | Dia. Mkgs. | Part No. | Description | |
| 1 | 271781 | Insulator, Heat/Sink Wrapper | 1 | |
| 2 | 221497 | Bumper, Polyurethane .500 Od x .140 High Adh Backed | 1 | |
| 3 | 271799 | Pin, Retaining .188 Od x 2.125 Lg | 2 | |
| 4 | 146549 | Rivet, Plastic .122 Hole x .039-.079 Grip Push | 1 | |
| 5 | 208622 | Label, Warn Elect Shock/Explod Parts/Do Not Remove | 1 | |
| 6 | 275817 | Strap, Handle/Shoulder Assy | 1 | |
| 7 | 195666 | Screw, 010-32 x .50 Pan Hd-Torx w/Gndrng St Pld | 2 | |
| 8 | 277200 | Label, Warning General Precautionary (En/Fr/Sp) | 1 | |
| 9 | 271784 | Wrapper | 1 | |
| 10 | 278902 | Cable, Power 2.0m 14Ga 3c 5-15p (125V/15A) To SDG | 1 | |
| 11 | 278903.. | Cable, Power 2.0m 12Ga 3c 5-50p (250V/50A) To SDG | 1 | |
| 12 | RC1 | 274991 | Receptacle, SDG 2.5mm Panel Mount Housing w/Leads | 1 |
| 13 | 277017 | Cover, Receptacle | 1 | |
| 14 | 275059 | Nameplate, Maxstar 161 (Rear) | 1 | |
| 15 | 208558 | Term, Frict .250 x .032 Uninsul Male 10-32 Mtg 45 Deg | 2 | |
| 16 | 219967 | Valve, 14 VDC 2way .625-18 Thd 2.2mm Orf 90 PSI | 1 | |
| 17 | 271790 | Hose, Poly Clew .170 Id x .250 Od x 11.000in. w/Clamps | 1 | |
| 18 | 208535 | Screw, K5Ox 12 Rnd Wshr Hd – Trx SU Pld Delta Pt | 4 | |
| 19 | PC3 | 274565 | Circuit Card Assy, 6 Pin Remote w/Cmpnts | 1 |
| 20 | PC2 | 272651 | Circuit Card Assy, User Interface | 1 |
| 21 | PC4 | 228593 | Circuit Card Assy, Arc Starter (CE) | 1 |
| 22 | PC1 | 278311 | Circuit Card Assy, Windtunnel w/Cmpnts | 1 |
| 23 | 271783 | Panel, Rear | 1 | |
| 24 | FM | 271789 | Fan, Muffin 24 VDC 92x38mm 5400 Rpm | 1 |
| 25 | 206258 | Relay, End 24 VDC SPST303/24 VDC 4-Pin Flange Mtg | 1 | |
| 26 | 275818 | Tape, Adh Double Sided 3M VHB .045in. x lin. Square | 1 | |
| 27 | 273761 | Windtunnel, Magnetics Assy w/HF | 1 | |
| 28 | 208552 | Insulator, Negative Stud | 1 | |
| 29 | 146549 | Rivet, Plastic .122 Hole x .039-.079 Grip Push | 1 | |
| 30 | 271781 | Base (Order by Model and Serial Number) | 1 | |
| 31 | 208497 | Nut, M5-.8 x 12mm Hex 8.3mm T Stl PId Sem Con Washer | 1 | |
| 32 | 271782 | Panel, Front | 1 | |
| 33 | 208561 | Work Clamp, w/Cable & Connector – 10 Ft | 1 | |
| 34 | 208596.. | Holder, Electrode w/Cable & Connector | 1 | |
| 35 | 273483.. | Adapter, Torch-Intnl Style Flow Thru | 1 | |
| 36 | 244862.. | Screw, M5-.8 x 12 Soc Hd – Torx StI PId Sems Piloted | 1 | |
| 37 | 208588.. | Nut, .625-27 .81 Hex .14 H Thermoplastic Black | 1 | |
| 38 | NEG | 208612.. | Rcpt Assy, Tw Lk Power/Gas Female Neg | 1 |
| 39 | 230052 | Knob, .840 Dia x 6mm Id w/Spring Clip – 4.5 | 1 | |
| 40 | POS | 271791 | Receptacle, Twist Lock Brass Power Female (Pos) | 1 |
| 41 | 208589 | Cover, Dust Receptacle | 1 | |
| 42 | 273310 | Nameplate, Maxstar 161 (Front) | 1 | |
| 43 | 254151 | Nut, M07-.75 10mm Hex 2mm H SO PId | 1 | |
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
For product information, Owner’s Manual translations, and more, visit
www.MillerWelds.com
Miller Electric Mfg. LLC An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters-USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
ORIGINAL INSTRUCTIONS – PRINTED IN USA
© 2020 Miller Electric Mfg. LLC 2020-01
