July
1980
FORM:
OM-1515A
Effective
With
Style
No.
HH-1
MODEL
GL-4O~
FLE
COPY
RETURN
~
~LDER
OVVN
ERî‚’S
MANUAL
MILLER
ELECTRIC
MFG.
Co.
)18
S
BOUNDS
ST.
P.O
Box
1079
APPLE]ON,WI
54912
USA
ADDITIONAL
COPY
PRICE
20
CENTS
NWSA
CODE
NO.
4519
PRINTED
IN
U.S.A.
î‚—
-
--
--î‚—--aî‚—î‚—î‚—.
.
.;
--___!-___:~__.
.-
_..
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(î‚‘
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millerî‚’s
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millerî‚’s
option
Ii)
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
All
Miller
service
station
or
(41
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
lless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customerî‚’s
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
i~
Except
as
specified
below,
Millerî‚’s
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
S
to
components
having
normal
useful
life
of less
than
one
(II
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
inent
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
componeiits
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Ilabor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NO~
FOR
CONSUMERS
OR
~s
CONSUMER
USE.
MILLERî‚’
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
30)
days
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERî‚’S
WARRANTIES
TO,
ANY
CONSUMER.
î‚‘T
~
~,
~
~,
~
.~,
.,~.
..~,.
SECTION
1
-
INTRODUCTION
Rating:
60%
Duty
Cycle
Wire
Diameter
Cooling
Method
Cable
Length
Net
Weight
Ship
Weight
400
Amperes
1/16î‚”,
5/64î‚”,
and
3/32î‚”
Air
9
lbs.
(4.08
kilos)
11
lbs.
(5.00
kilos)
,
15
11
lbs.
(4.99
kilos)
13
lbs.
(5.90
kilos)
Figure
1-1.
Specifications
1-1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description,
Stock
Number,
and
Style
Number
of
the
equipment
be
sup
plied.
1-3.
DESCRIPTION
-
This
gun
is
designed
specifical
ly
for
use
with
self-shielding
Flux-Cored
Arc
Welding
(FCAW)
process
using
self-shielding
flux-cored
elec
trodØ.
The
gun
may
be
used
for
either
DC
straight
or
DC
reverse
polarity
applications.
All
necessary
components
for
the
specific
wire
size
ordered
are
shipped
with
the
gun.
The
contact
tube
is
the
only
component
that
needs
to
be
changed
when
a
wire
size
change
is
desired.
1-4.
SAFETY
-
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
CAUTION
___________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
~
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
t~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
2-1.
INSTALLATION
OF
MONOCOIL
LINER
1.
Lay
gun
cable
out
straight.
2.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly
against
wire
straightener
(in
head
tube
behind
contact
tube;
see
Parts
List
for
view).
3.
Tighten
set
screw
in
head
tube
(via
clearance
hole
on
top
of
handle)
and
in
cable
connector.
Do
not
overtighten.
4.
If
the
monocoil
liner
protrudes
from
the
cable
connector,
cut
the
liner
off
flush
with
the
end
of
the
cable
connector.
2-2.
INSTALLATION
OF
GUN
TRIGGER
SWITCH
PLUG
1.
Make
connections
from
the
gun
trigger
switch
cord
to
the
plug
for
the
wire
feeder
as
follows:
A.
MM
10
and
30
Series:
Attach
the
two
wires
to
the
two
terminals
on
the
plug;
tighten
screws;
slide
insulator
onto
plug.
B.
LN-7
and
LN-8:
Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
the
two
wires
to
pins
A
and
C
on
the
five-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
C.
LN-22:
Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
the
two
wires
to
pins
A
and
C
on
the
three-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
D.
AA:
Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
the
two
wires
to
pins
A
and
D
on
the
four-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
OM-l5l5Pagel
E.
Ash-21:
Slide
the
cable
clamp
(strain
relief)
3.
Loosen
adapter
securing
device
on
the
drive
onto
the
cord;
solder
the
two
wires
to
pins
A
assembly
of
the
wire
feeder.
and
C
on
the
three-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
4.
Insert
adapter
into
adapter
housing
of
wire
feeder
as
close
to
the
drive
rolls
as
possible
F.
Swingarc,
Porta-Mig,
and
50
Series:
Slide
without
touching.
the
cable
clamp
(strain
relief)
onto
the
cord;
solder
or
crimp
the
two
pins
to
the
cable
and
5.
Tighten
adapter
securing
device.
push
the
pins
into
holes
1
and
2
on
the
four-
pin
plug;
secure
clamp
to
plug
body;
tighten
6.
Connect
the
plug
installed
in
Section
2-2
to
the
screws.
gun
switch
receptacle
on
wire
feeder.
2.
When
the
connections
have
been
properly
7.
Connect
the
remaining
end
of
the
interconnec
made,
the
plug
is
ready
to
be
attached
to
the
ting
power
cable
to
the
weld
cable
terminal
on
wire
feeder
gun
switch
receptacle,
wire
feeder,
where
applicable.
____________
Prior
to
installing
the
gun,
ensure
that
the
wire
feeder
and
we/ding
power
source
are
both
com
pletely
disconnected
from
their
respective
input
elec
trical
power
supplies.
2-3.
GUN
TO
WIRE
FEEDER
CONNECTIONS
1.
Slide
one
end
of
the
interconnecting
power
cable
onto
the
threads
on
end
of
cable
connector,
where
applicable.
2.
Thread
adapter
onto
cable
connector
and
tighten.
CAUTION
2-4.
CHANGING
WIRE
SIZE
-
The
contact
tube
is
the
only
component
in
the
gun
that
needs
to
be
chang
ed
to
accommodate
a
different
wire
size.
The
contact
tube
is
threaded.
To
remove,
rotate
in
a
counterclockwise
direction.
-
2-5.
NOZZLE
-
A
nozzle
(1-3/4î‚”)
is
recommended
for
normal
applications.
If
longer
stick
out
of
the
electrode
is
desired,
a
longer
nozzle
(2-3/8î‚”)
is
available
(see
Parts
List).
Should
very
close
work
be
done
where
the
nozzle
is
not
desired,
a
thread
protector
is
available
for
use
when
the
nozzle
is
removed
(see
Parts
List).
SECTION
3
-
MAINTENANCE
î‚—
Ensure
that
the
we/ding
power
source
is
b.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly
against
wire
straightener
(in
head
tube
behind
contact
tube;
see
Parts
List
for
view).
c.
Tighten
set
screw
in
head
tube
and
in
cable
connector.
Do
not
overtighten.
d.
If
a
new
monocoil
liner
has
been
installed,
cut
the
liner
off
flush
with
the
end
of
the
cable
connector.
e.
Reinstall
interconnecting
power
cable,
where
applicable.
f.
Reinstall
adapter.
3-2.
INSPECTION
AND
UPKEEP
-
Usage
and
con
ditions
will
determine
the
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice.
3.
Repair
or
replace
cables
as
required;
give
par
ticular
attention
to
frayed
and
cracked
insulation
and
areas
where
the
cables
enter
equipment.
4.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cables.
completely
shut
down
and
that
power
is
removed
from
the
wire
feeder
prior
to
performing
any
maintenance
procedures.
3-1.
CLEANING
MONOCOIL
LINER
-
Periodically,
depending
on
usage
and
conditions,
it
will
be
necessary
to
clean
the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
To
clean,
proceed
as
follows:
1.
Remove
monocoil
liner
as
follows:
a.
Remove
adapter
from
cable
connector.
b.
Remove
interconnecting
power
cable
from
cable
connector,
where
applicable.
c.
Remove
set
screw
from
cable
connector
and
from
head
tube
(via
clearance
hole
on
top
of
handle).
d.
Lay
cable
out
straight,
and
pull
monocoil
liner
out
from
feeder
end.
2.
Blow
monocoil
liner
out
with
clean,
dry,
com
pressed
air.
3.
Blow
casing
out
in
same
manner.
4.
Reinstall
monocoil
liner
as
follows:
a.
Lay
cable
out
straight.
Page
2
CAUTION
PARTS
LIST
July
1980
FORM:
OM-1515A
Effective
With
Style
No.
HH-1
MODEL
GL-40
31
Figure
A
-
Complete
Assembly
TC-052
230
e
p
2
3
4
5
67
1
30
13
23 24
29
28
26
OM-1515
Page
1
1
601
957
2
052
066
3
076
762
4
000 369
5
052
064
6
052
884
7
052
072
8
052
074
9
052
098
10
052059
10
052078
10
052075
11
009709
11
052055
11
008926
11
045356
12
052
060
13
052095
14
601
856
15
602207
16
601
865
17
052068
18
052090
18
052091
19
053076
20
005
177
21
052 063
22
052
883
23
052
092
24
052
058
24
080 925
24
052 056
24
052
057
24 053 788
25
604
523
25 073 329
25 073
509
073
331
25
052 236
039 828
25
052 237
073
332
25
079
878
079
535
048 834
26 052
086
26
052
087
27
053
132
28
081
580
28
081 581
29
052
071
30
057
544
31
052919
1
1
.2
1
1
1
1
1
1
1
1
.1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
Item
No.
Part
No.
Description
Quantity
Figure
A
Complete
Assembly
SCREW,
cap
-
steel
hex
hd
1/4-20
x
1-1/2
HANDLE,
gun
-left
hand
PIN,
spring
-
compression
SWITCH,
limit
10
amp
125/250
volts
ac
SPDT
TRIGGER,
gun
SCREW,
set
-
steel
socket
hd
10-32
x
1/4
TUBE,
head
(8
inch)
INSERT,
straightener
-
wire
SCREW,
set-
steel
hollow
3/8-16
x3/16
PROTECTOR,
thread
or
NOZZLE,
screw
1-3/4
or
NOZZLE,
screw
2-3/8
TUBE,
contact
1/l6wireor
TUBE,
contact
5/64
or
TUBE,
contact
3/32
wire
TUBE,
contact
0.045
wire
SHIELD,
hand
SCREW,set-steelsockethd5/16-18x1/2
NUT,
weld
5/16-18
WASHER,
lock
-
steel
split
1/4
NUT,
steel
-
hex
full
1/4-20
HANDLE,
gun
-
right
hand
CABLE/CONDUIT,
10
ft
or
CABLE/CONDUIT,
l5ft
CLAMP,
hose
1
inch
clamp
dia
STRAIN
RELIEF
CONNECTOR,
cable
-
gun
SCREW,
set
-
steel
socket
hd
10-32
x
3/8
CABLE,
connecting
-
power
(MM
10
&30
Series)
ADAPTER,
gun/feeder
1/16-3/32
(MM
10
&30
Series)
or
ADAPTER,
gun/feeder
1/16-3/32
(Swingarc,
Porta-Mig
&50
Series)
or
ADAPTER,
gun/feeder
1/16-3/32
(AA)
or
ADAPTER,
gun/feeder
1/16-5/64
(LN-7,
8
&
22)
or
ADAPTER,
gun/feeder
1/16-3/32
(ASH-21)
CAP,
twistlock
-
midget
2P2W
(MM
10
&30
Series)
PLUG,
4
pin
97-3106A-18-4P
(AA)
PLUG,
3
pin
MS-3106A-18-22P
(ASH-21)
CLAMP,
cable
(AA
&
ASH-21)
PLUG,
3
pin
MS-3106A-14S-1P
(LN-22)
CLAMP,
cable
(LN-22)
PLUG,
5
pin
MS-3106A-18-11P(LN
7
&8)
CLAMP,
cable
(LN
7
&8)
HOUSING
PLUG
&
PINS
(Swingarc,
Porta-Mig
&
50
Series)
(consisting
of)
TERMINAL,
male
CLAMP,
cable
(Swingarc,
Porta-Mig
&
50
Series)
CORD,
trigger
lift
or
CORD,
trigger
16
ft
STRAIN
RELIEF,
cable
LINER,
monocoil
0.23
OD
x
0.03-1/8
wire
11
ft
or
LINER,
monocoil
0.23
OD
xO.03-1/8
wire
16
ft
CLAMP,
head
tube
SPRING,
compression
SCREW,
machine
-
round
hd
1/4-20
x
7/8
Parts
For
Optional
Equipment
7
052
419
TUBE,
head
-
long
(12
inches)
7
046
143
TUBE,
head
80
deg
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-151.5
Page
2.
C
/