January
1979
FORM:
OM-1023A
FOLE
COPY
RETURN
TO
FOLDER
OWN
ERS
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
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYSubject
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
Millers
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
Millers
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
manufacturers
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
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
Except
as
specified
below,
Millers
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
MILLERS
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
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
Owners
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
Owners
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
Owners
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
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
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
Owners
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
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
Owners
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
1
1 1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
5
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1
1
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
5
1
1
1
1
1
1
1
5
5
1
1
1
1
1
1
1
1
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
1
1
1
OM-1023
Page
2
Figure
A
Gun
Assembly
(Contd.)
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
1
1
1
1
1
1
1
1
1
1 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
1
23
056
479
SPRING,
strain
relief
1
1
1
1
1
1
24
602
088
SCREW,
machine
-
steel
round
hd
10-32
x
1/4
.
.
-
1
1
1 1 1
1
25
056
834
HOSE
ASSEMBLY,
gas
10
ft
or
1 1
1 1
1 1
25
056
835
HOSE
ASSEMBLY,
gas
15
ft
(consisting
of)
1
1
1
1
1
1
26
056 848
.
FITTING,
hose-
brass
barbed
nipple
3/16
TBG
..
1
1
1 1 1
1
27
056
849
.
FITTING,
hose
-
brass
nut
No.
10
3/8-24
RH
..
.
1
1
1
1
1
1
28
056
108
.
FITTING,
hose
-
brass
ferrule
0.425
ID
x
23/32
.
2
2 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.
lOft.
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
1
1
1
1
1
31
056
851
.
FITTING,
hose
-
brass
barbed
nipple
3/16
TBG
.
.
1
1
1
1 1
1
32
057 782
CORD
ASSEMBLY,
switch
8
ft
2
inches
or
1
1
1
1
1
1
32
057
783
CORD
ASSEMBLY,
switch
13
ft
2
inches
(consisting
of)
1
1
1
1
1
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
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
2
2
2
2
2
37
056
830
SWITCH
&
HOUSING
ASSEMBLY
(consisting
of)
1
1
1
1 1
1
38
604 848
.
TERMINAL,
disk~
knife
16-22
wire
2
2
2
2 2
2
39
056
296
.
TUBING,
plastic
No.
4
2
2 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
1
1
1
42
059
294
.
SPRING,
compression
1
1
1
1
1
1
43
053
132
.
STRAIN
RELIEF,
cable
1
1 1
1
1
1
44
059
258
.
BLOCK,
mounting
-
switch
1
1
1
1
1
1
45
056
845
.
HOUSING,
switch
-
torch
1
1
1
1
1
1
46
056
846
.
LEVER,
actuating
-
switch
torch
1
1
1
1 1
1
47
059
290
.
NUT,
speed
-
push
on
1
1 1
1
1
1
48
059
293
.
RIVET,
steel
-flared
hd
7/32
dia.
x
1-1/4
1
1
1
1 1
1
49
604
937
SCREW,
self
-
tapping
pan
hd
6-32
x
1/4
2
2
2
2
2
2
50
604
607
SCREW,
machine
-
steel
10-32
x
3/4
1
1
1
1 1
1
056
815
056
817
056
816
056
818
056
819
t057
737
1 1
1
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
1
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 1 1
2
2
2
lOft.
10
ft.
10
ft.
15
ft.
15
ft.
15
ft.
1
1
OM-1023
Page
4
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