Miller 5088B GUN Owner's manual

Miller
Brand
Miller
Model
5088B GUN
Type
Owner's manual

This manual is also suitable for

October
1977
FORM:
OM-1511D
OWNERS
MANUAL
1!!!!
~
\
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,WI
54912
USA
ADDITIONAL
COPY
PRICE
50
CENTS
F~UE
COPY
RETU~
~
~~1LDER
MODEL
STOCK
NO.
3160B
Gun
.045
Hard
&
1/16
Hard
&
5/64
Hard
&
3/32
Hard
&
7/64
Hard
&
1/8
Hard
&
3700B
Gun
.035
Soft
053
100
3/64
Soft
053
101
1/16
Soft
053
102
3/32
Soft
053103
.045
Hard
053
104
1/16
Hard
053
108
5/64
Hard
053
109
3/32
Hard
053.110
7/64
Hard
053111
1/8
Hard
053112
~
3868B
Gun
.030
053 097
.035
053098
.
.045
053 099
5088B
Gun
.035
Hard
053
105
.045
Hard
053
106
1/16
Hard
053
107
Flux
053091
Flux
053092
Flux
053093
Flux
053094
Flux
053095
Flux
053096
1689A
Gun
With
7
Inch
Extension
052
848
052
849
052
850
052
851
052
852
052
853
052
854
With
12
Inch
Extension
052
855
052
856
052
857
052
858
052
859
052
860
052861
1/16
3/32
1/8
5/32
3/16
7/32
1/4
1/16
3/32
1/8
5/32
3/16
7/32
114
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
%
t~~
L~
LIMITED
WARRANTY
EFFECTIVE:
JANUARY
1,1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
d
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
with
respect
to
engines,
trade
accessories
or
other
items
manu-
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replacement
or,
factured
by
others.
Such
engines,
trade
accessories
and
other
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
items
are
sold
subject
to
the
warranties
of
their
respective
manu-
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
ser
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
(I)
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
and
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
original
user:
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
. .
1
year
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRIT-
)
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/guns
90
da~n
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
PANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
the
date
of
such
failure.
ANY
CONSUMER.
S
.-
.
~.
....,~
-...
.....
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
INTRODUCTION
1
-
1.
General
2
1
-
2.
Receiving-Handling
2
1
-
3.
Description
2
1-4.
Safety
2
SECTION
2
INSTALLATION
2-1.
Model
37005
Gun
2
2
-
2.
Model
31605
Gun
3
2
-
3.
Model
38685
Gun
4
2-4.
Model
1689A
Gun
5
2-5.
Model5O88BGun
6
PARTS
LIST
SECTION
1
-
INTRODUCTION
Model
3700B
Rating:
100%
Duty
Cycle,
DCRP
Capacity
Wire
Dia.
Cooling
Method
Net
Weight
Ship
Weight
500
Amp
CO2
400
Amp
Argon
Or_Mixes
.035
1/8
Circulated
Coolant
41b.
51b.
3160B
500
Amp
CO2
.045
-
1/8
Air
2
lb.
3
lb.
3868B
350
Amp
CO2
.030
-
.045
Air
1-1/21b.
2-1/21b.
1689A
800
Amp
1/16-
1/4
Air
31b.
4lb.
50888
400
Amp
CO2
.035
-
1/16
Air
1-3/41b.
2-3/41b.
Model
1689A
(Submerged-Arc)
Approximately
2
of
gun
tube
required
for
mounting
into
weld
head.
DIa.
TA-009
023-A
TA-009
021-A
Model
3700B
(Water-Cooled)
Model
3160B
Approximately
2
of
gun
tube
required
for
mounting
into
weld
head.
.7/8
009
022
Model
3868B
TA-009
025
P9/16
5/8
Figure
1-1.
Specifications
Model
5088B
TA-009
024-A
OM-1511
Page
1
1-3.
DESCRIPTION
I
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal-Arc
(GMAW)
Welding
process.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered,
Through
minor
changes
in
parts
the
gun
may
be
used
with
various
other
sizes
of
wire.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
Figure
2-1.
Model
3700B
Gun
SECTION
2
-
INSTALLATION
A.
Gun
To
Weld
Head
Installation
1
.
Vertical
Feed
Weld
Head
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
b.
Insert
the
extension
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
outlet
guide
is
within
about
1/16
of
the
weld
head
drive
rolls.
c.
Rotate
the
gun
within
the
weld head
gun
hole
until
desired
gun
orientation
is
obtained,
d.
Tighten
the
two
gun
securing
screws
on
the
weld
head
to
secure
the
gun
on
the
weld
head.
e.
Make
proper
gas
hose
connections.
f.
Make
proper
coolant
hose
connections.
g.
Connect
the
power
cable
from
the
welding
power
source
to
the
weld
cable
terminal
on
the
gun;
tighten
securely.
L_
Ensure
that
the
welding
power
source
is
electrically
shut
down
before
making
connections
to
the
weld
cable
terminal.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
welding
power
source
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
welding
power
source
by
employing
machinery
lockout
procedures
before
attempting
this
connection.
If
the
welding
power
source
is
connected
to
a
disconnect
switch,
padlock
the
switch
in
an
open
position.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
i
others
that the
circuit
is
being
worked
on.
CAUTION
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.
Under
this
heading,
installation,
opera~,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per-
sonnel.
I
I
I
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.
1-4.
SAFETY
I
I
I
I
to
installing
any
of
the
guns,
ensure
that the
welding
power
source
and
the
control/feeder
are
de
energized.
I
2-1.
MODEL
3700B
GUN
(Figure
2-1)
2
3
.4
Id
Cable
Shielding
Gas
Connector
I
I
TB-003
622-A
Page
2
2-2.
MODEL
3160B
GUN
(Figure
2-2)
A.
Gun
To
Weld
Head
Installation
1.
Vertical
Feed
Weld
Head.
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
b.
Insert
the
extension
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
outlet
guide
is
within
about
1/16
of
the
weld head
drive
rolls.
c.
Rotate
the
gun
within
the
weld head
gun
hole
until
desired
gun
orientation
is
obtained.
d.
Tighten
the
two
gun
securing
screws
on
the
weld
head
to
secure
the
gun
on
the
weld
head.
e.
Make
proper
gas
hose
connections.
f.
Connect
the
power
cable
from
the
welding
power
source
to
the
weld
cable
terminal
on
the
gun;
tighten
securely.
CAUTION
U
Ensure
that
the
welding
power
source
is
electrically
shut
down
before
making
connections
to
the
weld
cable
terminal.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
welding
power
source
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
welding
power
source
by
employing
machinery
lockout
procedures
before
attempting
this
connection.
If
the
welding
power
source
is
connected
to
a
disconnect
switch,
padlock
the
switch
in
an
open
position.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
others
that
the
Circuit
iS
being
worked
on.
flTANT
r
Ensure
that
the
contacting
surfaces
of
the
weld
cable
terminals
are
kept
clean
at
all
times.
Also
ensure
that
the
bolts
on
these
terminals
are
secure.
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
could
result.
i
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
i
2.
Horizontal
Feed
Weld
Head.
This
gun
is
shipped
for
use
on
a
vertical
feed
weld
head,
If
it
is
desired
to
use
this
same
gun
with
a
horizontal
feed
weld
head,
the
following
modifications
must
be
made
on
the
gun:
1.
Remove
the
outlet
guide
(item
1,
Figure
2-2),
liner
(2),
and
extension
(3).
2.
Retain
the
jam
nut
(4)
and
the
weld
cable
terminal
in
their
positions
for
future
use.
a.
Rotate
jam
nut
(4)
Onto
ball
joint,
and
place
weld
cable
terminal
into
proper
position
on
ball
joint.
b.
Rotate
the
gun
threaded
female
connector
clockwise
Onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
c.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
d.
Loosen
the
two
ball
joint
adjustment
securing
screws.
e.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
f.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
NOTE
For
horizontal
feed
weld
head
applications,
the
supplied
monocoil
liner
must
be
cut
off
to
the
proper
length
according
to
the
following
instructions
g.
Remove
nozzle
(10)
from
gun.
h.
Remove
contact
tube
(9).
i.
Slide
monocoil
liner
(part
of
outlet
cable
assembly)
through
ball
joint
and
gun,
allowing
outlet
cable
to
fit
into
proper
position
on
ball
joint.
j.
Cut
monocoil
liner
off
flush
with
nozzle
end
of
head
tube.
k.
Slide
monocoil
liner
out
of
gun,
and
cut
5/16
more
off
the
same
end
(end
where
initial
cut
was
made
in
Step
j).
I.
Reinstall
liner
(and
outlet
cable),
contact
tube,
and
nozzle.
Secure
outlet
cable
and
liner
in
position.
B.
Shielding
Gas
Connections
Connect
the
shielding
gas
hose
connector
from
the
weld
control
to
the
gun
shielding
gas
connector
(shielding
gas
connector
is
illustrated
in
Figure
2-2).
These
connectors
have
right-hand
threading.
C.
Outlet
Guide,
Liner,
Contact
Tube,
And
Nozzle
Installation
Upon
initial
installation,
as
a
result
of
component
wear,
or
when
changing
from
one
welding
wire
size
to
another,
one
or
more
of
the
following
items
will
need
to
be
changed:
outlet
guide,
liner,
and
contact
tube.
Refer
to
the
Parts
List
for
the
proper
combination
of
these
components
for
a
particular
welding
wire
size
and
proceed
with
the
following
instruc
tions:
1.
Disassembly
a.
Release
the
tension
on
the
weld
head
drive
rolls
and
manually
retract
the
welding
wire
from
the
gun.
b.
For
gun
mounted
on
vertical
feed
weld head
only:
Remove
the
gun
from
the
weld
head.
Remove
the
outlet
guide
(item
1,
Figure
2-2),
and
the
liner
(2).
c.
Remove
the
nozzle
(10),
if
necessary.
d.
Remove
the
contact
tube
(9).
2.
Assembly
a.
Reverse
Steps
la
thru
ld
(Disassembly),
referring
to
Section
2-2,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
or
Section
2-2,
A.
2
for
gun
to
horizontal
feed
weld
head
installation.
2-3.
MODEL3868B
GUN
(Figure
2-3)
A.
Gun
To
Weld
Head
Installation
1.
Vertical
Feed
Weld
Head.
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
b.
Insert
the
extension
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
outlet
guide
is
within
about
1/16
of
the
weld
head
drive
rolls.
c.
Rotate
the
gun
within
the
weld
head
gun
hole
until
desired
gun
orientation
is
obtained.
d.
Tighten
the
two
gun
securing
screws
on
the
weld
head
to
secure
the
gun
on
the
weld
head.
Page
4
TB-003
623-A
f.
Connect
the
power
cable
from
the
welding
power
source
to
the
weld
cable
terminal
on
the
gun;
tighten
securely.
I
Ensure
that
the
welding
power
source
is
electrically
U
shut
down
before
making
connections
to
the
weld
cable
terminal.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
welding
power
source
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
welding
power
source
by
employing
machinery
lockout
procedures
before
attempting
this
connection.
If
the
welding
power
source
is
connected
to
a
disconnect
switch,
padlock
the
switch
in
an
open
position.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
others that
the
circuit
is
being
worked
on.
r~~TANT
II
Ensure
that
the
contacting
surfaces
of
the
weld
cable
terminals
are
kept
clean
at
all
times.
Also
ensure
that
the
bolts
on
these
terminals
are
secure.
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
could
result
IMPORTANT
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
i
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld
Head.
Figure
2-3.
Model
3868
B
Gun
e.
Make
proper
gas
hose
connections,
NOTE
This
gun
is
shipped
for
use
on
a
vertical
feed
weld
head.
If
it
is
desired
to
use
this
same
gun
with
a
horizontal
feed
weld
head,
the
following
modifi
cations
must
be
made
on
the
gun:
1.
Remove
the
outlet
guide
(item
1,
Figure
2-3),
liner
(2),
and
extension
(3).
2.
Retain
the
jam
nut
(4)
and
the
weld
cable
terminal
in
their
positions
for
future
use.
a.
Rotate
jam
nut
(4)
onto
ball
joint,
and
place
weld
cable
terminal
into
proper
position
on
ball
joint.
b.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
c.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
d.
Loosen
the
two
ball
joint
adjustment
securing
screws.
e.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
f.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
~rizontaI
f
eed
w&d
head
applications,
the
supplied
monocoil
liner
must
be
cut
off
to
the
proper
length
according
to
the
following
instructions
g.
Remove
nozzle
(6)
and
insulator
(7)
from
gun.
h.
Remove
contact
tube
(5).
i.
Slide
monocoil
liner
(part
of
outlet
cable
assembly)
through
ball
joint
and
gun,
allowing
outlet
cable
to
fit
into
proper
position
on
ball
joint.
j.
Cut
monocoil
liner
off
flush
with
nozzle
end
of
head
tube.
k.
Slide
monocoil
liner
out
of
gun,
and
cut
5/16
more
off
the
same
end
(end
where
initial
cut
was
made
in
Step
j).
I.
Reinstall
liner
(and
outlet
cable),
contact
tube,
insula
tor,
and
nozzle.
Secure
outlet
cable
and
liner
in
position.
B.
Shielding
Gas
Connection
Connect
the
shielding
gas
hose
connector
from
the
weld
control
to
the
gun
shielding
gas
connector
(shielding
gas
connector
is
illustrated
in
Figure
2-3).
These
connectors
have
right-hand
threading.
C.
Outlet
Guide,
Liner,
Contact
Tube,
And
Nozzle
Installation
Upon
initial
installation,
as
a
result
of
component
wear,
or
when
changing
from
one
welding
wire
size
to
another,
one
or
more
of
the
following
items
will
need
to
be
changed:
outlet
guide,
liner,
contact
tube,
and
shielding
gas
nozzle.
Refer
to
the
Parts
List
for
the
proper
combination
of
these
compo
nents
for
a
particular
welding
wire
size
and
proceed
with
the
following
instructions:
1.
Disassembly
a.
Release
the
tension
on
the
weld head
drive
rolls
and
manually
retract
the
welding
wire
from
the
gun
b.
For
gun
mounted
on
vertical
feed
weld
head
only:
Remove
the
gun
from
the
weld
head.
Remove
the
out
let
guide
(item
1,
Figure
2-3)
and
the
liner
(2).
c.
Remove
the
nozzle
(6).
and
insulator
(7),
if
used.
.3
2
.4
.5
.
U
OM-1511
Pages
d.
Remove
the
contact
tube
(5).
2.
Assembly
a.
Reverse
Steps
la
thru
ld
(Disassembly),
referring
to
Section
2-3,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
if
applicable.
24.
MODEL
1689A
GUN
(Figure
24)
A.
Gun
To
Weld Head
Installation
1.
Vertical
Feed
Weld
Head.
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
b.
Slide
extension
of
gun
through
flux
hopper
mounting
bracket.
c.
Insert
the
extension
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
extension
is
within
about
1/16
of
the
weld head
drive
rolls.
d.
Rotate
the
gun
within
the
weld
head
gun
hole
until
desired
gun
orientation
is
obtained.
e.
Tighten
the
two
gun
securing
screws
on
the
weld
head
to
secure
the
gun
on
the
weld
head.
f.
Connect
the
power
cable
from
the
welding
power
source
to
the
weld
cable
terminal
on
the
gun;
tighten
securely.
Extension
Figure
2-4.
Model
1689A
Gun
Ensure
that
the
welding
power
source
is
electrically
shut
down
before
making
connections
to
the
weld
cable
terminal.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
welding
power
source
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
welding
power
source
by
employing
machinery
lockout
procedures
before
attempting
this
connection,
If
the
welding
power
source
is
connected
to
a
disconnect
switch,
padlock
the
switch
in
an
open
position.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
others
that
the
circuit
is
being
worked
on.
that
t
he
the
weld
cable
contacting
surfaces
of
terminals
are
kept
clean
at
all
times.
Also
ensure
that
the
bolts
on
these
terminals
are
secure,
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
i
could
result.
flTANT
Ensure
that
the
tip
of
the
gun
extension
does
not
touch
the
weld
head
drive
rolls.
B.
Extension
And
Contact
Tube
Installation
Upon
initial
installation,
as
a
result
of
component
wear,
or
when
changing
from
one
welding
wire
size
to
another,
the
extension
and/or
the
contact
tube
will
need
to
be
changed.
Refer
to
the
Parts
List
for
the
proper
combination
of
these
components
for
a
particular
welding
wire
size
and
proceed
with
the
following
instructions:
1.
Disassembly
a.
Release
the
tension
on
the
weld
head
drive
rolls
and
manually
retract
the
welding
wire
from
the
gun.
b.
For
gun
mounted
on
vertical
feed
weld head
only:
Remove
the
gun
from
the
weld
head.
Remove
the
ex
tension.
c.
Remove
the
contact
tube
by
first
removing
the
con
tact
tube
securing
nut,
and
loosening
the
two
contact
tube
setscrews.
2.
Assembly
a.
Reverse
Steps
la
thru
lc
(Disassembly),
referring
to
Section
2-4,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
if
applicable.
Ensure
that
the
contact
tube
keyway
aligns
with
the
gun
body
key.
2-5.
MODEL
5088B
GUN
(Figure
2-5)
A.
Gun
To
Weld
Head
Installation
1.
Vertical
Feed
Weld
Head
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
U
Terminal
~ntact
Tube
TB-003
620
I
Weld
Cable
Terminal
Shielding
Gas
Connector
TB-003
621-A
Figure
2-5.
Model
5088B
Gun
Page
6
b.
Insert
the
extension
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
outlet
guide
is
within
ebout
1/16
of
the
weld
head
drive
rolls.
c.
Rotate
the
gun
within
the
weld
head
gun
hole
until
desired
gun
orientation
is
obtained.
d.
Tighten
the
two
gun
securing
screws
on
the
weld
head
to
secure
the
gun
on
the
weld
head.
e.
Make
proper
gas
hose
connections.
f.
Connect
the
power
cable
from
the
welding
power
source
to
the
weld
cable
terminal
on
the
gun;
tighten
securely.
~re
that
the
wel,..ing
power
sour~
electrically
shut
down
before
making
connections
to
the
weld
cable
terminal.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
welding
power
source
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
welding
power
source
by
employing
machinery
lockout
procedures
before
attempting
this
connection.
If
the
welding
power
source
is
connected
to
a
disconnect
switch,
padlock
the
switch
in
an
open
position.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
i
others
that
the
circuit
is
being
worked
on.
r~
~RTAN~,
Ensure
that
the
contacting
surfaces
of
the
weld
cable
terminals
are
kept
clean
at
all
times.
Also
ensure
that
the
bolts
on
these
terminals
are
secure.
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
could
result.
.1
I
~ORTAN~~
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld Head
.
This
gun
is
shipped
for
use
on
a
vertical
feed
weld
head.
If
it is
desired
to
use
this
same
gun
with
a
horizontal
feed
weld
head,
the
following
modifications
must
be
made
on
the
gun:
1.
Loosen
the
liner
securing
setscrew
(item
5,
Figure
2-5).
2.
Remove
the
outlet
guide
(1),
liner
(21,
and
extension
(3).
3.
Retain
the
jam
nut
(4)
and
the
weld
cable
terminal
in
their
positions
for
future
use.
a.
Rotate
jam
nut
(4)
onto
ball
joint,
and
place
weld
cable
terminal
into
proper
position
on
ball
joint.
b.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
c.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
d.
Loosen
the
two
ball
joint
adjustment
securing
screws.
e.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
-
f.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
onta
I
f
aed
w&d
h
ead
a
pplications,
the
supplied
monocoil
liner
must
be
cut
off
to
the
proper
length
according
to
the
following
instructions
g.
Remove
contact
tube
(6).
h.
Slide
monocoil
liner
(part
of
outlet
cable
assembly)
through
ball
joint
and
gun,
allowing
outlet
cable
to
fit
into
proper
position
on
ball
joint.
i.
Cut
monocoil
liner
off
flush
with
nozzle
end
of
head
tube.
j.
Slide
monocoil
liner
out
of
gun,
and
cut
5/16
more
off
the
same
end
(end
where
initial
cut
was
made
in
Step
il.
k.
Reinstall
liner
(and
outlet
cable),
and
contact
tube.
Secure
outlet
cable
and
liner
in
position.
B.
Shielding
Gas
Connection
Connect
the
shielding
gas
hose
connector
from
the
weld
control
to
the
gun
shielding
gas
connector
(shielding
gas
connector
is
illustrated
in
Figure
2-5).
These
connectors
have
right-hand
threading.
C.
Outlet
Guide,
Liner,
And
Contact
Tube
Installation
Upon
initial
installation,
as
a
result
of
component
wear,
or
when
changing
from
one
welding
wire
size
to
another,
one
or
more
of
the
following
items
will
need
to
be
changed:
outlet
guide,
liner,
and
contact
tube.
Refer
to
the
Parts
List
for
the
proper
combination
of
these
components
for
a
particular
welding
wire
size
and
proceed
with
the
following
instruc
tions:
1.
Disassembly
a.
Release
the
tension
on
the
weld
head
drive
rolls
and
manually
retract
the
welding
wire
from
the
gun.
b.
For
gun
mounted
on
vertical
feed
weld
head
only:
Remove
the
gun
from
the
weld
head.
Loosen
the
liner
securing
setscrew
(item
5,
Figure
2-5).
Remove
the
outlet
guide
(1)
and
the
liner
(2).
c.
Remove
the
contact
tube
(6).
2.
Assembly
a.
Reverse
Steps
la
thru ic
(Disassembly),
referring
to
Section
2-5,
A,
1
for
gun
to
vertical
feed
weld
heed
installation,
if
applicable.
OM-1511
Page
7
October
1977
FORM:
OM-1511D
MODEL
035
Soft
3/64
Soft
1/16
Soft
3/32
Soft
.045
Hard
1/16
Hard
5/64
Hard
3/32
Hard
7/64
Hard
1/8
Hard
.030
.035
.045
.035
Hard
.045
Hard
1/16
Hard
STOCK
NO.
3700B
Gun
053
100
053
101
053
102
053
103
053
104
053
108
053
109
053110
053
111
053112
3868B
Gun
053
097
053
098
053
099
5088B
Gun
053
105
053
106
053
107
MODEL
STOCK
NO.
3160B
Gun
.045
Hard
&
Flux
053
091
1/16
Hard
&
Flux
053
092
5/64
Hard
&
Flux
053
093
3/32
Hard
&
Flux
053
094
7/64
Hard
&
Flux
053
095
1/8
Hard
&
Flux
053
096
1689A
Gun
With
7
Inch
Extension
1/16
052
848
3/32
052 849
1/8
052850
5/32
052
851
3/16
052
852
7/32
052
853
1/4
052854
With
12
Inch
Extension
1/16
052
855
3/32
052
856
1/8
052857
5/32
052858
3/16
052
859
7/32
052
860
1/4
052861
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON?
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
4
~
9
1
13
14
21
-11
12
20
15
18
Figure
A
Exploded
View
Of
Model
3700B
Gun
TC-039
280-C
OM-1511
Page
1
Quantity
ModeL
Soft
Wire
Hard
or
Fluxed
Cored
Wire
.9MM
1.2MM
1.6MM
2.4MM
1.2MM
1.6MM
2.0MM
2.4Mrvl2.8MM
3.2MM
Item
Factory
.035
.047 .063
.094
.047
.063
.078
.094
.110
.125
No.
Part
No.
Description
.035
3/64
1/16
3/32
.045
1/16
5/64
3/32
7/64
1/8
Figure
A
Exploded
View
Of
Model
3700B
Gun
1
053
328
FITTING,
brass
-
flared
elbow
male3/16TBGx1/8NPT
1
1
1
1
1
1
1
1
1
1
2
053324B0DY
1
1
1
1
1
1
1
1
1
1
3
053
325
FITTINCI,
hose
-
brass
adapter
1/8NPT3/8-24RH
1
1
1
1
1
1
1 1 1 1
4
052
771
GUIDE,
wire
-
outlet
1
4
009452
GUIDE,wire.outlet
1
4
009
454
GUIDE,
wire
-
outlet
1
4
009
453
GUIDE,
wire
-
outlet
1
4
077
286
GUIDE,
wire
outlet
1
4
075
783
GUIDE,
wire
.
outlet
1
1
1
4
053
178
GUIDE,
wire
-
outlet
1
1
5
053
171
LINER,
nylon
12-5/8
inches
Ig
1
5
053
174
LINER,
nylon
12-5/8
inches
Ig
1
1
5
053
172
LINER,
nylon
12-5/8
inches
Ig
1
5
053
163
LINER,
monocoil
12-7/8
inches
1g
1
5
053
158
LINER,
monocoil
12-5/8
inches
1g..
1
5
053
152
LINER,
monocoil
12-5/8
inches
1g
1
1
6
075773
EXTENSION
1
1
1
1
1
1 1 1
1
1
7
601
883
NUT,
steel
.
hex
jam
5/8-18
1
1
1
1 1
1
1
1
1
1
8
O75774BUSBAR
1
1
1
1
1
1
1
1
1
1
9
075
599
NUT,
brass
-
hex
5/8-18
x
1-1/4
LG
1
1
1
1 1
1
1
1
1
1
10
053
317
NUT,
mounting
nozzle
1
1 1
1
1
1
1
1 1 1
11
053319
TUBE,head
1
1
1
1 1 1
1
1
1
1
12
053314
TUBE,water-outlet
1
1
1
1 1 1
1
1 1
1
13
057
592
FITTINCI,
brass
-
compression
nut
3/16TBG
3 3
3 3 3
3
3
3
3
3
14
057
591
FITTING,
brass
-
compression
sleeve
3/16TBG
3
3
3
3
3
3
3
3
3
3
15
056821
TUBE,contact
.035
wire
3
15
056
822
TUBE,
contact
.045
&
3/64
wire
3 3
15
056823
TUBE,contact
1/16
wire
3
3
15
053
177
TUBE,contact3/32wire
3
3
15
056
824
TUBE,
contact
5/64
wire
3
15
053
175
TUBE,contact
7/64
wire
3
15
053
176
TUBE,
contact
1/8
wire
3
16
SEE
OPTIONAL
EQUIPMENT
17
SEE
OPTIONAL
EQUIPMENT
18
SEE
OPTIONAL
EQUIPMENT
19
075
765
NOZZLE,
5/8
orifice
x
2
1
1
1
1
1
1
1
1 1 1
20
053
323
BODY,
head
-
tube
1
1
1
1
1
1
1
1 1 1
21
075
831
TUBE,
inlet
-
water
1
1
1
1
1
1 1
1 1
1
Parts
tor
Optional
Equipment
Refer
To
Figure
A
On
Page
1
For
Identification
Of
Item
Numbers
5
053
165
LINER,
monocoil
15-5/8
inches
long
1
5
053
166
LINER,
monocoil
20-5/8
inches
long
1
5
053
159
LINER,
monocoil
15-5/8
inches
long
1
5
053
157
LINER,
monocoil
20-5/8
inches
long
1
5
053
153
LINER,
monocoil
15-5/8
inches
long
1
1
5
053
154
LINER,
monocoil
20-5/8
inches
long
1
1
6
079
323
EXTENSION,
3
inches
1
1
1
1
1
1
6
079
324
EXTENSION,
8
inches
1
1
1 1
1
1
16
075
763
NOZZLE,
5/8
orifice
x
2-5/16
inches
1
1 1 1
1
1
1
1
1
17
075
764
NOZZLE,
5/8
orifice
x
2-1/8
inches
1
1
1
1
1
1
1
1
1
1
18
079
097
NOZZLE,
1
inch
orifice
x
2-1/2
inches
1
1 1
1
1
1
1
1
1
1
BE
SURE
TO
PROVIDE
STOCK,
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1511
Page
2
31
32
33
34
35
36
~
37
Figure
B
Exploded
View
Of
Model
3160
B
Gun
TC-039
276-A
38
39
38
40
42
Page
3
Item
Factory
No.
Part
No.
Description
Figure
B
Exploded
View
Of
Model
3160
B
Gun
31
077286
31
075783
31
053178
32
053168
32
053155
32
053151
33
075773
34
601
883
35
075774
36
075599
37
075671
38
073779
39
053331
40
053
330
41
056822
41
056823
41
056824
41
053177
41
053175
41
053176
42
075
659
GUIDE,
wire
-
outlet
GUIDE,
wire
-
outlet
GUIDE,
wire
-
outlet
LINER,
monocoil
9-7/16
inches
Ig
LINER,
monocoil
9.7/16
inches
Ig
LINER,
monocoil
9-7/16
inches
Ig
EXTENSION
NUT,
steel
-
hex
jam
5/8-18
BUS
BAR
NUT,
brass
-
hex
5/8-18
x
1-1/4
NUT,
body
WASHER,
flat-
phenolic
5/8
ID
x
1.110
OD
x
3/16
TUBE,
head
BODY,
head
-
tube
TUBE,
contact
-
screw
045
wire
TUBE,
contact
-
screw
1/16
wire
TUBE,
contact
-
screw
5/64
wire
TUBE,
contact
-
screw
3/32
wire
TUBE,
contact
-
screw
7/64
wire
TUBE,
contact
-
screw
1/8
wire
NOZZLE,
screw
-
type
5/8
orifice
x
15/16
ID
x
2-3/8
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
2
.2
2 2
2
1 1
1 1
1
1
1 1 1 1
3
Parts
For
Optional
Equipment
Refer
To
Figure
8
Page
3
For
Identification
Of
Item
Numbers
32
053164
32
053167
32
053
160
32
053156
32
053149
32
053150
33
079323
33
079
324
LINER,
monocoil
12-7/l6Ig
LINER,
monocoil
17-7/16
Ig
LINER,
monocoil
12-7/16
Ig
LINER,
monocoil
17-7/16
Ig
LINER,
monocoil
17-7/16
Ig
LINER,
monocoil
12-7/16
Ig
EXTENSION
EXTENSION
1 1
1 1
1 1
1
1
1
1
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Quantity
Model
1.2MM
L6MM
2.0MM
2.4MMJ2.8MM13.2MM
.047
.063
.078
.094
I
.110
I
.125
.045
1/16
5/64
3/32t7/64t1/8
1
1
.1
1
1
1
1
1
1
1
1
1
2
1
1
3
1
3
3
3
3
1 1
1
1
1
1
1
1
1
1
1 1
OM-1511
Page
4
66
61
Figure
C
Exploded
View
Of
Mdoel
38688
Gun
TC-039
278-A
59
!60
64
62
Page
5
Item
Factory
No.
Part
No.
Description
Quantity
Model
.8MM .9MM
1.2MM
.031
.035
.047
.030
.035 .045
Figure
C
Exploded
View
Of
Model
3868B
Gun
51
51
*
52
53
53
54
55
56
57
58
59
60
61
61
61
62
63
64
65
66
53
053169
53
053173
57
053234
58
075867
62
075 896
63
075
895
64
075
893
65
075
894
66
+075
906
1
1
1
1
1
1
1 1
1
1
1 1
1
1
1 1
1
1
1 1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
+This
Item
Is
Used
With
075
893
And
075
894
Only.
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
009
455
009 456
075
773
053
170
009
474
601
883
075
774
075 863
053235
075866
075
905
075
890
056
820
056
821
056
822
GUIDE,
wire
-
outlet
GUIDE,
wire
-
outlet
EXTENSION
LINER,
nylon
11-7/8
inches
Ig
LINER,
nylon
11-7/8
inches
Ig
NUT,
steel
-
hex
jam
5/8-18
BUS
BAR
ADAPTER,
extension/head
tube
TUBE,
head
INSULATOR,
head
tube
NUT,
nozzle
INSULATOR,
nozzle
TUBE,
contact
.030
wire
TUBE,
contact
.035
wire
TUBE,
contact
.045
wire
SEE
OPTIONAL
EQUIPMENT
SEE
OPTIONAL
EQUIPMENT
075
893
NOZZLE,
5/8
orifice
x
2-1/4
SEE
OPTIONAL
EQUIPMENT
075 906
INSULATOR,
nozzle
Parts
For
Optional
Equipment
Refer
To
Figure
C
On
Page
5
For
Identification
Of
Item
Numbers
LINER,
nylon
7-1/2
inches
Ig
LINER,
nylon
7-1/2
inches
Ig
TUBE,
head
INSULATOR,
head
tube
NOZZLE,
5/8
orifice
x
2-1/4
NOZZLE,
5/8
orifice
x
2-1/4
NOZZLE,
1/2
orifice
x
2-1/4
NOZZLE,
1/2
orifice
x
2-1/4
INSULATOR,
nozzle
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
0P4r1511
Page
6
Item
Factory
No.
Part
No.
Description
Quantity
Model
1.6MM
2.4MM
3.2MM
4.0MM
4.8MM
5.6MM
6.4MM
.063
.094
.125
.156
.187
.218
.250
1/16
3/32
1/8
5/32 3/16
7/32
1/4
Figure
0
Exploded
View
Of
Model
1689A
Gun
81
079116
81
079117
81
075595
81
075597
82
075
599
83
074
759
84
602009
85
075600
86
073 303
87
052
874
88
605
369
89
075601
90
078892
91
075603
91
075604
91
075605
91
075606
91
075607
EXTENSION,
7
inch
or
EXTENSION,
12
inch
EXTENSION,
7
inch
or
EXTENSION,
12
inch
NUT,
brass
-
hex
5/8-18
x
1-1/4
Ig
BUS
BAR
SCREW,
cap
-
steel
socket
hd
1/4-20
x
1-1/4
BLOCK,
spring
SPRING,
compression
BLADE,
nozzle
PIN,springl/4x1
inch
BLOCK,
blade
&
nozzle
SCREW,
set
-steel
socket
hd
3/8-16
x
3/8
TUBE,
contact
1/16
wire
TUBE,
contact
3/32
wire
TUBE,
contact
1/8
wire
TUBE,
contact
5/32
wire
TUBE,
contact
3/16
wire
1
1
1 1
1
1
1
1
1 1
1
1
1 1
1 1
2 2 2 2
2
2
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
2
2
2
2
2
2
Figure
D
Exploded
View
Of
Model
1689A
Gun
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1
1
1
1
2
1
1
1
1
1
2
1
91
075
608
TUBE,
contact
7/32
wire
91
075
609
TUBE,
contact
1/4
wire
1
1
83
TC-039
279
86
87
89
90
91
Page
7
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Miller 5088B GUN Owner's manual

Miller
Brand
Miller
Model
5088B GUN
Type
Owner's manual
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