Miller MMT-300A1 Owner's manual

January

1979

FORM:

OM-1023A

FOLE

COPY

RETURN

TO

FOLDER

OWN

ERS

MANUAL

~r

HilliER

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

30

CENTS

Effective

With

Style

No.

HJ-6

MODEL

M

MT-300A

1

MMT-400A1

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

~-

LIMITED

WARRANTY

(

ihis

wa~rant

EFFECTIVE:

JANUARY

1,1979

y

supersedes

all

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

to

submitted

by

the

original

user

within

the

foregoing

periods

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

by

Miller

is

free

from

defect

in

workmanship

and

material

as

of

the

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

time

and

place

of

delivery

by

Miller.

No

warranty

is

made

by

Miller

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefor

shall

be,

at

Millers

option,

(I)

repair

or

(2)

replacement

or,

with

respect

to

engines,

trade

accessories

or

other

items

manu-

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

the

factured

by

others.

Such

engines,

trade

accessories

and

other

items

are

sold

subject

to

the

warranties

of

their

respective

manu-

reasonable

cost

of

repair

or

replacement

at

an

authorized

Miller

5cr-

facturers,

if

any.

At

the

present

time,

the

manufacturers

warranty

on

vice

station

or

(4)

payment

of

or

credit

for

the

purchase

price

(less

the

Mag-Diesel

engine

on

DEL-200

is

limited

to

six

months

and

on

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

all

other

engines

to

one

year.

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

Except

as

specified

below,

Millers

warranty

does

not

apply

to

warranty

claim

procedures

to

be

followed.

components

having

normal

useful

life

of

less

than

one

(1)

year,

such

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

as

spot

welder

tips,

relay

and

contactor

points,MILLERMATIC

parts

ANY

IMPLIED

WARRANTY

GUARANTY

OR

REPRESENTA

~

that

come

in

contact

with

the

welding

wire

including

nozzles

arKi

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

nozzle

insulators

where

failure

does

not

result

from

defect

in

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

)

workmanship

or

material.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUS

TOM

OF

TRADE

OR

COURSE

OF

DEALING

INCLUDING

ANY

Miller

shall

be

required

to

honor

warranty

claims

on

warranted

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OROF

FITNESS

Equipment

in

the

event

of

failure

resulting

from

a

defect

within

the

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY AND

following

periods

from

the

date

of

delivery

of

Equipment

to

the

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

I.

Arc

welders,

power

sources

and

components

-

.

. .

I

year

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

WRIT-

)

original

user:

AND

DISCLAIMED

BY

MILLER.

2.

Original

main

power

rectifiers

3

years

ING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

(labor

-

1

year

only)

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

3.

All

welding

guns

and

feeder/ginis

90

da~

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

4.

All

other

Millermatic

Feeders

1

year

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor

. .

60

days

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLER

WAR-

6.

Batteries

-

6

months

provided

that Miller

is

notifled

in

writing

wIt~n

thi;ty(30)

days

of

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO,

RANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

the

date

of

such

failure.

ANY

CONSUMER.

~I1

-

~%

~

,f

~-

~,

._..,I,

~.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

Item

Part

No.

Listed

Replaced

With

No.

In

Parts

List

Part

No.

Description

Quantity

76

057168

056761

LINER,monocoil.O45wirel5ft

1

BE

SURE

TO

PROVIDE

MODEL,

STYLE

NUMBER

AND

WIRE

SIZE

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1023A

Page

A

SECTION

1

-

INTRODUCTION

Model

Ampere

Rating

100%

Duty

Cycle

dcrp

CO2

Argon

Cable

And

Hose

Length

Cooling

Method

Dimensions

In

Inches

Approx.

Weight

In

Pounds

Height

I

Length

Net

I

Shipping

300

Ampere

300

I

200

400

I

Amps. Amps.

Amps

10

Ft.

15

Ft.

Air

1

6-1/2

113-1/2

~

6-1/2

13-1/2

9

I

10

12

I

13

400

Ampere

10

Ft.

15

Ft.

Air

10

11

13

14

Before

the

equipment

is

put

into

operation,

the

safety

sec

tion

at

the

front

of

the

welding

power

source

or

welding

generator

manual

should

be

read

completely.

This

will

help

avoid

possible

injury

due

to

misuse

or

improper

welding

applications.

The

following

definitions

apply

to

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

I

~this

heading.

ins

tallation,

o1Ling,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

hazard

to

per



sonnel.



E~TANT

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result

in

damage

to

equip

ment.

Under

this

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the

most

efficient

operation

of

the

equipment.

SECTION

2

-

INSTALLATION

to

in

stalling

the

gun,

en

su

re

th

at

the

con

t

roll

feeder

and

welding

power

source

are

both

completely

disconnected

from

their

respective

input

electrical



power

supplies.

2-1.

GAS

HOSE

CONNECTIONS

(Figure

2-1)

Connect

the

gas

hose

from

the

gun

to

the

gas

connection

on

the

control/feeder

and

tighten.

This

fitting

has

a

fight-hand

thread.

2-2.

CONTROL

SWITCH

RECEPTACLE

(Figure

2-1)

Insert

the

two-prong

twistlock

plug

from

the

gun

control

cable

into

the

control

switch

receptacle

on

the

control/feeder

and

rotate

plug

clockwise.

2-3.

WELD

CABLE

CONNECTIONS

(Figure

2-1)

Connect

the

weld

power

cable

from

the

gun

to

the

weld

cable

connector

on

the

control/feeder.

Tighten

the

nut

on

this

connection.

2-4.

CONTACT

TUBE

AND

WIRE

GUIDE

Contact

tubes

usually

have

the

wire

size

they

are

designed

for

stamped

on

the

tube

body.

Check

the

contact

tube

to

make

sure

it

is

the

correct

size

for

the

wire

being

used.

Check

the

wire

guides

on

the

control/feeder

to

make

sure

they

are

the

correct

size.

2-5.

OUTLET

GUIDE

CONNECTIONS

A.

For

guns

to

be

used with

SWINGARC

SINGLE

or

SWINGARC

DUAL

units:

~tlet

gu

ide

in

stalled

to

the

adapter

mu

st

be

the

same

size

as

the

outlet

guide

on

the

gun.

1.

Screw

desired

size

outlet

guide

into

threaded

end

of

outlet

guide

adapter.

1-4.

SAFETY

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

in

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

of

this

equipment.

All

informa

tion

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

equipment,

it

is

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

1.3.

DESCRIPTION

This

gun

is

manufactured

in

two

model

classifications:

300

amp

and

400

amp.

Both

models

are

air

cooled

and

are

designed

specifically

for

the

Gas

Metal-Arc

Welding

(GMAW)

process.

The

design

features

of

the

300

amp

model

permits

use

of

.030,

.035,

.045

diameter

hard

wire

and

.045

diameter

flux

cored

wire.

This

gun

is

rated

at

300

amperes,

100

percent

duty

cycle

when

used

with

CO2

shielding

gas.

The

design

features

of

the

400

amp

model

permits

use

of

either

flux

cored

or

hard

wires

having

diameters

.045,

1/16,

and

5/64.

This

gun

is

rated

at

400

amperes,

100

percent

duty

cycle

when

used

with

CO2

shielding

gas.

The

gun

is

shipped

with

the

proper

components

installed

for

wire

size

ordered.

I

NOTE

I

OM-1

023

Page

1

2.

Insert

outlet

guide

on

the

gun

into

outlet

guide

adapter

with

flat

side

toward

set

screw.

Secure

adapter

tightening

setscrew.

3.

Proceed

to

Step

B1.

B.

For

guns

to

be

used

with

all

other

control/feeders:

(Figure

2-1)

1.

Ensure

that

proper

size

components

are

installed

in

the

gun

assembly

and

the

control/feeder

for

the

wire

size

being

used

(refer

to

respective

parts

list).

2.

Thread

the

electrode

wire

through

the

drive

roll

of

the

control/feeder

so

it

extends

about

3

inches

beyond

the

outlet

guide

hole.

3.

Close

and

secure

the

gear

cover(s).

4.

Slide

the

outlet

guide

over

the

wire

and

into

the

drive

roll

assembly

housing.

5.

Ensure

that

the

flat

side

of

the

outlet

guide

is

facing

the

setscrew.

The

outlet

guide

should

be

positioned

as

close

as

possible

to

the

drive

rolls

without

touching

them.

This

gives

the

maximum

column

wire

strength

thus

elimin

ating

waves

in

the

wire.

When

more

pressure

is

applied

at

any

time

the

clearance

should

be

rechecked

on

all

guides.

SECTION

3

-

SEQUENCE

OF

OPERATION

1.

Ensure

that

proper

electrical

connections

have

been

made

to

the

welding

power

source

and

the

control/

feeder

(refer

to

the

respective

Owners

Manuals).

2.

Ensure

that

the

proper

shielding

gas

is

connected

to

the

control/feeder.

3.

Ensure

that

the

welding

wire

has

been

properly

threaded

and

that

correct

initial

tensions

have

been

set

on

the

control/feeder

(refer

to

the

control/feeder

Owners

Manual).

4.

Turn

on

the

shielding

gas

supply.

5.

Place

controls

on

the

control/feeder

in

the

required

positions

for

the

welding

set

up.

6.

Energize

the

control/feeder

(the

welding

power

source

must

be

energized

if

the

control/feeder

power

input

is

connected

to

the

welding

power

source).

welding

!er

sou

me

is

e

nerg

ized

a

nd

the

switch

lever

on

the

gun

is

depressed,

open-circuit

~vltage

will

be

present

on

the

welding

wire

and

any

metal

part

making

contact

with

it.

rTANr

When

installing

new

equipment,

or

after

prolonged

shutdown,

allow

shielding

gas

to

flow

continuously

for

at

least

one

minute

prior

to

welding

in

order

to

purge

the

shielding

gas

line.

Place

the

Wire

Speed

control

to

the

minimum

setting

to

avoid

wasting

the

welding

wire

while

purging.

8.

Actuate

the

swtich

on

the

gun

handle

to

run

the

wire

out

beyond

the

end

of

the

gas

nozzle

(if

applicable).

Cut

the

wire

off

approximately

1/4

to

3/8

from

the

nozzle.

9.

Set

the

Wire

Speed

control

on

the

control/feeder

slightly

in

excess

of

anticipated

wire

speed.

~bett!rtohavet~~

e

wire

speed

rete

too

fast

than

too

slow.

If

the

wire

feed

rate

is

too

slow

upon

initial

welding,

the

wire

may

burn

back

into

the

contact



tube,

thus

damaging

it.

10.

Place

the

controls

on

the

welding

power

source

in

the

required

position

for

the

welding

set

up

(refer

to

welding

power

source

Owners

Manual).

11.

Energize

the

welding

power

source.

Prior

to

welding,

it

is

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and/or

welding

helmet)

be

put

on.

Failure

to

comply

may

result

in

serious

or

permanent

bodily



damage.

12.

Hold

the

end

of

the

gas

nozzle

approximately

1/2

from

the

workpiece.

6.

Tighten

the

locking

screws.

To

Outlet

Guide

Should

Not

Touch

Gears.

I

Weld

cable

connector

Assembly

3-1.

GAS

METAL-ARC

WELDING

(GMAW)

TC-O56

811-4

Figure

2-1.

Gun

to

Control/Feeder

Connections

I

I.

I

7.

Press

the

Purge

button

(if

applicable)

or

the switch

lever

on

the

gun

handle

to

purge

the

gas

line.

The

welding

wire

and

all

metal

parts

in

contact

with

it

are

energized

while

welding.

Do

not

touch

the

welding

wire

or

any

metal

part

making

contact

with

it.

Page

2

13.

Press

the

switch

lever

on

the

gun

handle.

Gas

will

start

to

flow,

wire

will

start

to

feed

and

the

arc

will

be

established.

If

wire

slippage

is

noticed,

tighten

drive

roll

pressure

adjustment

1/4

turn

at

a

time

until

slippage

stops.

Do

not

overtighten.

that

the

weld

ing

per

sou

rce

is

comp

lete

ly

shut

down

and

that

power

is

removed

from

the

control/feeder

prior

to

performing

drive

roll

pressure

adjustment.

I

fl~TA~

-

Whenever

drive

roll

pressure

is

adjusted

inlet

and

outlet

guide

clearance

must

be

rechecked.

14.

After

the

controls

on

the

welding

power

source

and

the

control/feeder

have

been

adjusted

for

normal

operation,

the

control/feeder

and

welding

power

source

will

function

automatically

whenever

the

gun

switch

is

depressed.

Releasing

the

gun

switch

lever

will

extinguish

the

arc

and

cause

wire

feed

and

gas

flow

to

stop.

If

welding

is

performed

in

a

confine~.

failure

to

turn

off

the

shielding

gas

supply

could

result

in

a

buildup

of

gas

fumes,

thereby

endangering

personnel

reentering

the

welding

area.

SECTION

4

-

MAINTENANCE

CAUTION

Ensure

that

the

welding

power

sour~

completely

shut

down

and

that

power

is

removed

from

the

control/feeder

prior

to

attempting

maintenance

work

i

on

this

gun

or

associated

equipment.

4-1.

INSPECTION

AND

UPKEEP

~gunisequippNOTE5wireanditis

ed

for

.030

or

.03

desired

to

convert

from

one

of

these

wire

sizes

to

the

other,

only

the

Contact

tube

(item

4,

Figure

4-1)

will

have

to

be

Changed.

However,

if

the

gun

is

equipped

for

.030

or

.035

wire

and

it is

desired

to

convert

to

.045

wire

(or

vice

versa),

all

of

the

following

steps

will

have

to

be

performed.

Usage

and

shop

conditions

will

determine

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.

Remove

any

accumulation

around

the

switch.

4.

Repair

or

replace

as

required

all

hose

and

cabling;

give

particular

attention

to

frayed

and

cracked

insulation

and

areas

where

it

enters

equipment.

5.

Remove

grease

and

grime

from

components;

moisture

from

electrical

parts

and

cables

6.

Blow

out

the

casing

with

compressed

air

when

changing

wire.

This

removes

any

metal

chips

and

dirt

that

may

have

accumulated.

4-2.

CHANGING

WIRE

SIZES

(Monocoil)(Figure

4-1)

Each

time

wire

size

is

changed,

the

gun

and

control/feeder

must

be

adapted

for

use

with

the

new

size

wire.

Refer

to

the

Control/Feeder

Owners

Manual

for

information

involving

changes

in

the

control/feeder

that

are

required

to

handle

different

wire

sizes.

Proceed

as

follows

when

changing

wire

size

with

the

monocoil

assembly

to

help

ensure

proper

installation.

1.

Cut

the

weld

bead

knob

off

the

end

of

the

welding

wire

at

the

gun

nozzle

(2).

2.

Loosen

the

outlet

guide

locking

screw

and

pull

the

outlet

guide

from

the

control/feeder

(Figure

2-1

).

3.

Cut

the

welding

wire

where

it

enters

the

outlet

guide

(19).

Pull

the

wire

out

of

the

monocoil

assembly

from

the

end

with

the

outlet

guide.

Remove

screw

(16)

and

strain

relief

(15).

Remove

nozzle

(2),

contact

tube

(4),

and

contact

tube

adapter

(5).

Install

new

items

in

reverse

order

just

given.

6.

Slide

insulating

band

(1)

off

gun

and

remove

flat

head

screw

(10).

7.

Pull

handle

(12)

back

about

six

inches.

Pull

switch

wires

back

along

with

handle

(12)

to

avoid

jamming.

8.

Remove

outlet

guide

(19).

9.

Loosen

setscrew

(18)

and

remove

monocoil

connector

(17).

10.

Loosen

setscrew

(9)

and

pull

monocoil

liner

(14)

out

of

outlet

guide

end

and

install

new

monocoil

liner

(14).

11.

Secure

monocoil

liner

(14)

by

tightening

setscrew

(9).

12.

Install

new

monocoil

Connector

(17)

securing

mono

coil

liner

(14)

to

monocoil

connector

(17)

by

tighten

ing

setscrew

(18).

13.

Slide

handle

(12)

onto

head

tube

(6)

and

secure

with

flat

head

screw

(10).

Slide

insulating

band

(1)

over

screw

(10).

14.

Install

outlet

guide

(19)

on

monocoil

connector

(17).

15.

Install

strain

relief

(15)

Onto

outlet

guide

(19)

and

secure

with

screw

(16).

3-2.

SHUTTING

DOWN

1.

Turn

off

the

shielding

gas

at

the

source.

U

2.

Deenergize

the

control/feeder

and

the

welding

power

source.

4.

5.

I

that

the

welding

power

sour~

completely

shut

down

and

that

power

is

removed

from

the

control/feeder

prior

to

changing

the

wire,

cornrol/

feeder

components,

or

gun

components.

OM-1

023

Page

3

Band,

Insulator

Nozzle

Insulator,

Nozzle

Tube,

Contact

Adapter,

Contact

Tube

Tube,

Head

Screw,

Set

10-32

x

3/8

Connector,

Conduit

or

Monocoil

Screw,

Set

10-32

x

3/16

(300

Amp

Model

Only)

Screw,

Machine

10-32

x

3/8

Switch

&

Housing

Assembly

Handle

Monocoil

Casing

(300

Amp

Models)

Conduit

(400

Amp

Models)

Liner,

Monocoil

Spring.

Strain

Relief

Screw,

Round

Head

10-32

x

1/2

Connector,

Monocoil

Screw,

Set

Guide,

Outlet

NOTE:

Items

8

&

9

assembled

at

factory.

TC-056

811-3

Figure

4-1.Installing

Conduit

AndMonocoil

Wire

Guide

Kits

16.

Install

outlet

guide

(19)

into

control/feeder

and

proceed

with

welding

operations.

4-3.

CHANGING

WIRE

SIZES

(Conduit)(Figure

4-1)

Ensure

that

the

welding

power

source

is

completely

shut

down

and

that

power

is

removed

from

the

control/feeder

prior

to

changing

the

wire,

control/

feeder

components,

or

gun

components.

Each time

wire

size

is

changed,

the

gun

and

control/feeder

must

be

adapted

for

use

with

the

new

size

wire.

Refer

to

the

Control/Feeder

Owners

Manual

for

information

involving

changes

in

the

control/feeder

that

are

required

to

handle

different

wire

sizes.

Proceed

as

follows

when

changing

wire

size

with

the

conduit

assembly

to

help

ensure

proper

installation.

NOTE

If

the

gun

is

equipped

for

1/16

or

5/64

wire

and

it

is

desired

to

convert

from

one

of

these

wire

sizes

to

the

other,

only

the

contact

tube

(item

4,

Figure

4-1)

will

have

to

be

changed.

However,

if

the

gun

is

equipped

for

1/16

or

5/64

wire

and

it

is

desired

to

convert

to

.045

wire

(or

vice

versa),

all

of

the

following

steps

will

have

to

be

performed.

1.

Cut

the

weld

bead

knob

off

the

end

of

the

welding

wire

at

the

gun

nozzle

(2).

2.

Loosen

the

outlet

guide

locking

screw

and

pull

the

outlet

guide

from

control/feeder

(Figure

2-1

).

3.

Cut

the

welding

wire

where

it

enters

the

outlet

guide

(19).

Pull

the

wire

out

of

the

conduit

(13)

from

the

end

with

the

outlet

guide.

4.

Remove

nozzle

(2),

contact

tube

(4),

and

contact

tube

adapter

(5).

Install

new

items

in

reverse

order

just

given.

5.

Slide

insulating

band

(1)

off

gun

and

remove

flat

head

screw

(10).

6.

Pull

handle

(12)

back

about

six

inches.

Pull

switch

wires

back

along

with

handle

(12)

to

avoid

jamming.

7.

Loosen

setscrew

(7)

and

pull

out

conduit

connector

(8)

from

head

tube

(6).

8.

Unscrew

conduit

connector

(8)

from

conduit

assembly

(13)

and

pull

conduit

assembly

(13)

out

of

gun

handle

(12).

9.

Remove

screw

(16)

from

outlet

guide

(19)

and

pull

off

strain

relief

(15).

10.

Unscrew

outlet

guide

(19)

from

conduit

(13).

11.

Install

new

outlet

guide

(19)

onto

conduit

(13).

12.

Secure

strain

relief

(15)

to

outlet

guide

(19)

with

screw

(16).

13.

Insert

the

new

conduit

(13)

through

the

bottom

of

handle

(12).

14.

Remove

0-Ring

from

connector

(8)

and

install

on

new

connector

(8)

if

applicable.

15.

Secure

new

conduit

connector

(8)

onto

the

conduit

(13).

16.

Slide

handle

(12)

onto

head

tube

(6)

and

secure

with

flat

head

screw

(10).

Slide

insulating

band

(1)

over

screw

(10).

17.

Install

outlet

guide

(19)

into

control/feeder

and

proceed

with

welding

operations.

1

LEGEND

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

7

8

14.

15.

16.

17.

18.

19.

12

17

16

Page

4

January

1979

FORM:

OM-1023A

PARTS

LIST

Effective

With

Style

No.

HJ-6

MODEL

MMT-300A1

MMT-400A1

3

132

Includes

Item

36

2

1

49

.4

Includes

Item

10

15

9

374~

S

26

27

28

~25

28

30

31

J

TC-056

811-C

Figure

A



Gun

Assembly

(400

Ampere

Conduit

Model

Illustrated)

OM-1023

Page

1

Item

Factory

No.

Part

No

Figure

A

Gun

Assembly

300

Amp

Monocoi

I

Wire

Size

1

*056

710

2

056816

2

056818

3

054 572

4

007319

4

007

321

4

007318

4

007

320

4

007317

4

007

322

4

056

895

4

056

900

4

056

896

4

056901

4

056

897

4

056

902

5

*056

820

5

*056

821

5

056

822

5

*056

823

5

*056

824

6

056

825

6

056

826

7

007

330

7

007

332

8

058

174

9

056

652

9

056

653

9

056619

9

056621

9

057

218

9

057

220

10

057083

10

056741

10

056836

11

058190

12

058192

13

058

191

14

604771

15

056610

16

602090

17

056831

18

056832

18

056833

1 1

1

1 1

1

1 1

1

1 1

1

1 1

1

5

1

1 1

1

Quantity

Model

Description

400

Amp

Conduit

.8MM

.9MM

.031

.035

.030

.035

Wire

Size

1.2MM

.047

.045

1.2MM

1.6MM

2.0MM

.047

.063

.079

.045

1/16

5/64

1

5

1

5

1

1 1

1

INSULATOR,

nozzle

11/16

inch

NOZZLE,

5/8

orifice

2-5/8

long

NOZZLE,

5/8

orifice

2-3/4

long

BAND,

rubber

1-1/18

ID

x

3/64

wide

x

3/4

KIT-WIRE,

guide

.030

10

ft

or

KIT-WIRE,

guide

.O30wire

l5ft

(See

Fig.

B

Page

4)

KIT-WIRE,

guide

.035

wire

10

ft

or

KIT-WiRE,

guide

.035

wire

lSft

(See

Fig.

B

Page

4)

KIT-WIRE,

guide

.045

wire

lOft

or

KIT-WIRE,

guide

.045

wire

lSft

(See

Fig.

B

Page

4)

KIT-WIRE,

guide

.045

wire

lOft

or

KIT-WIRE,

guide

.045

wire

15

ft

(consisting

of)

KIT-WIRE,guide

1/l6wire

lOftor

KIT-WIRE,

guide

1/16

wire

15

ft

(consisting

of)

KIT-WIRE,

guide

5/64

wire

10

ft

or

KIT-WIRE,

guide

5/64

wire

15

ft

(consisting

of)

TUBE,

contact

.030

wire

x

1-5/8

TUBE,

contact

.035

wire

x

1-5/8

-

TUBE,

contact

.045

wire

x

1-5/8



TUBE,

contact

1/16

wire

x

1-5/8

.TUBE,contact5/64wirex

1-5/8



ADAPTER,

tube

-

contact

.030-.045

wire

ADAPTER,

tube

-

contact

1/16

x

5/64

wire

-

CONNECTOR,

monocoil

(consisting

of)

CONNECTOR,

conduit

(consisting

of)

..O-RING,1/4x3/8



CONDUIT,

.080

ID

x

10

ft

or

.CONDUIT,.O8OIDxl5ft



CONDUIT,

0.124

ID

x

10

ft

or



CONDUIT,

0.124

ID

x

15

ft

MONOCOIL

ASSEMBLY,

.030

&

.035

10

ft

or

MONOCOIL

ASSEMBLY,

.030

&

.035

15

ft

(See

Fig.

B

Page

4)

9

057219

.MONOCOILASSEMBLY,.045

lOftor

9

057

221

-

MONOCOIL

ASSEMBLY,

.045

15

ft

(See

Fig.

B

Page

4)



GUIDE,

outlet

.030

&

.035

wire

-

GUIDE,

outlet

.045

wire



GUIDE,

outlet

1/16

x

5/64

wire

TUBING,

neoprene

5/8

ID

x

3/32

wall

x

4-5/8

INSULATOR,

body

-

head

tube

TUBE,

head

SCREW,

set

-

steel

10-32

x

1/8

LINER,

tube

head

SCREW,

machine

-

steel

flat

hd

10-32

x

3/8

HANDLE

CABLE

ASSEMBLY,

welding

10

ft

or

CABLE

ASSEMBLY,

welding

15

ft

(consisting

of)

1

OM-1023

Page

2

Figure

A

Gun

Assembly

(Contd.)

Optional

Parts

NOZZLE,

1/2

orifice

2-5/8

long

NOZZLE,

1/2

orifice

2-3/4

long

NOZZLE,

5/8

orifice

2-5/8

long

NOZZLE,

5/8

orifice

2-3/4

long

NOZZLE,

3/4

orifice

2-3/4

long

TUBE,

contact

.052

wire

*

Recommended

Spare

Parts.

1

1 1

1

1 1

1

tCan

be

used

with

.045

wire

guide

kits.

BE

SURE

TO

PROVIDE

MODEL,

STYLE

NUMBER

AND

WIRE

SIZE

WHEN

ORDERING

REPLACEMENT

PARTS.

Page

3

Item

Factory

No.

Part

No.

Quantity

Model

300

Amp

Monocoil

Description

400

Amp

Conduit

.8MM

.031

.030

Wire

Size

Wire

Size

1

1

.9MM

.035

.035

.2MM

.047

.045

.2MM

.047

.04

5

1.6MM

2.0MM

.063 .079

1/16

5/64

I

19

056

443

.

CONNECTOR,

torch

end

1

1 1

1

1 1

20

600

330

.

CABLE,

weld

-

copper

stranded

No.

1/0

hypalon

(order

by

ft.)

10

ft.

10

ft.

10

ft.

10

ft.

10

ft.

10

ft.

20

21

600

330

056 803

.

CABLE,

weld

-

copper

stranded

No.

1/0

hypalon

(order

by

ft.)

.

LUG.

swedge

on

1/0-2/0

cable

15

ft.

1

15

ft.

1

15

ft.

1

15

ft.

1

15

ft.

1

15

ft.

1

22

056

854

.

TUBING,

heat

shrink

3/8

dia

x

2.1/2

1

1 1 1

1

23

056

479

SPRING,

strain

relief

1

24

602

088

SCREW,

machine

-

steel

round

hd

10-32

x

1/4

.

-

1

1 1 1

1

25

056

834

HOSE

ASSEMBLY,

gas

10

ft

or

1 1

25

056

835

HOSE

ASSEMBLY,

gas

15

ft

(consisting

of)

1

26

056 848

.

FITTING,

hose-

brass

barbed

nipple

3/16

TBG

..

1

1 1 1

1

27

056

849

.

FITTING,

hose

-

brass

nut

No.

10

3/8-24

RH

..

.

1

28

056

108

.

FITTING,

hose

-

brass

ferrule

0.425

ID

x

23/32

.

2

2 2

2

29

604

550

.

HOSE,

neoprene

No.

1

x

3/16

ID

(order

by

ft.)

or

10

ft.

lOft.

10

ft.

lOft.

29

604

550

.

HOSE,

neoprene

No.

1

x

3/16

ID

(order

by

ft.)

.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

30

010606

.FITTING,hose-brassnut5/8-18RH

1

31

056

851

.

FITTING,

hose

-

brass

barbed

nipple

3/16

TBG

.

1

1 1

1

32

057 782

CORD

ASSEMBLY,

switch

8

ft

2

inches

or

1

32

057

783

CORD

ASSEMBLY,

switch

13

ft

2

inches

(consisting

of)

1

33

604

523

.

CAP,

twistlock

-

midget

2P2W

1 1

1

1 1

1

34

604

524

.

COVER,

seal

-

tite

receptacle

1

1 1

1

35

604

525

.

CORD,

portable

18/2

(order

by

ft.)

or

9

ft.

9

ft.

9

ft.

9

ft.

9

ft.

9

ft.

35

604

525

.

CORD,

portable

18/2

(order

by

ft.)

14

ft.

14

ft.

14

ft.

14

ft.

14

ft.

14

ft.

36

604848

TERMINAL,disk-

knife

16-22

wire

2

37

056

830

SWITCH

&

HOUSING

ASSEMBLY

(consisting

of)

1

1 1

1

38

604 848

.

TERMINAL,

disk~

knife

16-22

wire

2

2 2

2

39

056

296

.

TUBING,

plastic

No.

4

2

2 2

2

40

604

525

.

CORD,

portable

No.

18

2/C

(order

by

ft.)

3

ft.

3

ft.

3

ft.

3

ft.

3

ft.

3

ft.

41

604 866

.

SWITCH,

licon

16-3022

1 1

1

42

059

294

.

SPRING,

compression

1

43

053

132

.

STRAIN

RELIEF,

cable

1

1 1

1

44

059

258

.

BLOCK,

mounting

-

switch

1

45

056

845

.

HOUSING,

switch

-

torch

1

46

056

846

.

LEVER,

actuating

-

switch

torch

1

1 1

1

47

059

290

.

NUT,

speed

-

push

on

1

1 1

1

48

059

293

.

RIVET,

steel

-flared

hd

7/32

dia.

x

1-1/4

1

1 1

1

49

604

937

SCREW,

self

-

tapping

pan

hd

6-32

x

1/4

2

50

604

607

SCREW,

machine

-

steel

10-32

x

3/4

1

1 1

1

056

815

056

817

056

816

056

818

056

819

t057

737

1 1

1

Item

Factory

No.

Part

No.

Figure

B

Monocoil

Assemblies

Description

Quantity

.8MM

.9MM

1.2MM

.031

.035

.047

.030

.035

.045

71

057

307

71

057

308

72

057

309

73

602

959

74

056112

75

605

545

75

605

545

76

056

758

76

056

760

76

056

759

76

057

168

77

058

679

77

058680

78

058174

1

71

72

73

74

75

76

74

77

78

Figure

B



Monocoil

Assembly

TA-057

072-B

BE

SURE

TO

PROVIDE

MODEL,

STYLE

NUMBER

AND

WIRE

SIZE

WHEN

ORDERING

REPLACEMENT

PARTS.

CONNECTOR,

monocoil

CONNECTOR,

monocoil

FITTING,

brass

-

barbed

liner

FITTING,

hose

-

brass

nut

9/16-18

FITTING,

hose

-

brass

ferrule

0.475

ID

x

23/32

TUBING,

neoprene

17/64

ID

x

1/2

OD

(order

by

ft.)

or

TUBING,

neoprene

17/64

ID

x

1/2

OD

(order

by

ft.)

LINER,

monocoil

.030

&

.035

wire

10

ft

or

LINER,

monocoil

.045

wire

10

ft

or

LINER,

monocoil

.030

&

.035

wire

15

ft

or

LINER,

monocoil

.045

wire

15

ft

CONNECTOR,

monocoil

.030

&

.035

wire

CONNECTOR,

monocoil

.045

wire

O-RING,1/4x3/8

1

1 1 1

2

lOft.

10

ft.

10

ft.

15

ft.

15

ft.

15

ft.

1

OM-1023

Page

4

Miller MMT-300A1 Owner's manual

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