Miller MMT-210A Owner's manual

March

1974

FORM:

OM-1024

ADDITIONAL

COPY

PRICE

25

CENTS

.030

Wire

.035

Wire

.045

Wire

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

10

Ft.

058

554

058

555

058

556

15

Ft.

058

557

058

558

058

559

Effective

with

Style

No.

HE-i

MODEL:

MMT-210A

NWSA

CODE

NO.

4579

U

5

5.



~1

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M(

X

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LX

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C

~

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C

~

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~

CD

C)

CD

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

all

new

equipment

to

be

free

from

defects

in

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

is

installed

and

C

)

CD

operated

according

to

manufacturers

instructions.

CD

MILLER

Electric

Mfg.

Co.s

obligation,

under

this

warranty,

is

limited

to

replacing

or

repairing

any

defective

part

or

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

if

MILLERS

inspec-

C

)

C)

tion

confirms

the

existence

of

such

defects.

MILLERS

option

of

repair

or

replacement

will

bef.o.b.

factory

at

c

Appleton,

Wisconsin

or

f.o.b.

a

MILLER

authorized

service

facility,

and

therefore

no

compensation

for

trans

I

~

portationcostsofanykindwillbeallowed.

C)

The

warranty

period,

beginning

on

the

date

of

sale

to

the

original

purchaser-user

of

the

equipment,

will

be

as

I

~

follows:

c

1

Arc

welders,

power

sources,

and

components



1

year

C

C)

2.

Original

main

power

rectifiers



3

years

(unconditionally)

3.

MHFC-L1

Feeder,

MHG-35C1,

20E,

20K,

C

I

~

CD

and

all

guns

and

torches



90

days

c )

4.

All

other

Millermatic

Feeders



1

year

5.

Mag-Diesel

engine

on

DEL-200



6

months

C

C)

U

~

6.

All

other

engines



1

year

c

U

C)

Engine

Warranties

are

covered

by

the

engine

manufacturers,

subject

to

their

procedures

and

to

be

handled

C)

through

their

authorized

local

Service

Stations

or

agencies.

No

warranty

will

be

made

in

respect

to

trade

accessories,

such

being

subject

to

the

warranties

of

their

respective

manufacturers.

C

I

U

C)

I

)

-

C)

U

C)

MILLER

Electric

Mfg.

Co.

will

not

be

liable

for

any

loss

or

consequential

damage

or

expense

accruing

c

directly

or

indirectly

from

the

use

of

equipment

covered

in

this

warranty.

U

C

~

U

C)

I

This

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

C

U

C)

U

warranties

expressed

or

implied.

c

U

C)

_______________________________________________________________

Q

p

tQ

Q1.Q..P.J

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SECTION

1

-

INTRODUCTION

Rating:

100

PCT.

Duty

Cycle,

dcrp

Wire

Dia.

Cable

And

Hose

Length

Cooling

Method

Net

Weight

Ship

Weight

200

Amperes

.030

To

10

Air

8

lbs.

12

oz.

10

lbs.

5

oz.

With

CO2

.045

Hard

15

Air

11

lbs.

8oz,

13

lbs.

Figure

1-1.

Specifications

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

designed

specifically

for

use

in

conjunction

with

the

Gas

Metal-Arc

(MIG)

Welding

process.

The

gun

is

shipped

assembled

for

the

specific

wire

size

ordered.

Through

minor

changes

in

parts

the

gun

may

be

used

with

.030, .035.

or

.045

wire.

1-4.

SAFETY

The

following

definitions

apply

to

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

this

h

eading,

installation,

operating

,

a

nd

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

safety

hazard

to

personnel.

fl~ORT~T

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

or

practices

will

be

found

that

if

no,t

carefully

followed

may

result

in

damage

to

equip

meht.

I~..r=~-1

.1

Under

this

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the

most

efficient

operation

of

the

equipment.

SECTION

2-

INSTALLATION

CAUTION_-~

Prior

to

installing

the

gun,

ensure

t~econtrol/

feeder

and

welding

power

source

are

both

completely

disconnected

from

the

respective

input

electrical

power

supplies.

2-4.

OUTLET

GUIDE

CONNECTION

(Figure

2-1)

Insert

the

outlet

guide

from

the

gun

into

the

outlet

guide

hole

on

the

control/feeder.

Ensure

that

the

flat

surface

on

the

outlet

guide

is

facing

the

securing

screw

on

the

control/

feeder.

Prior

to

securing

the

outlet

guide

in

the

control/

feeder,

ensure

that

the

tip

of

the

outlet

guide

is

1/16

away

from

the

drive

rolls.

2-1.

SHIELDING

GAS

HOSE

CONNECTION

(Figure

2-1)

Secure

the

shielding

gas

hose

connector

in

the

shielding

gas

output

connector

on

the

control/feeder

or

to

whatever

de

vice

that

is

to

be

used

for

on-off

control

of

the

shielding

gas.

The

shielding

gas

hose

connector

has

right

hand

threading.

2-2.

GUN

SWITCH

CONNECTION

(Figure

2-1)

Insert

the

two

-

prong

plug

from

the

Gun

Switch

fully

into

the

Switch

Control

Receptacle

on

the

control/feeder.

Once

fully

inserted

into

the

receptacle,

rotate

the

plug

as

far

as

it

will

turn

in

a

clockwise

direction;

this

will

lock

the

plug

in

the

receptacle

and

prevent

the

plug

from

coming

out

under

tension.

2-3.

WELD

CABLE

CONNECTION

(Figure

2-1)

Attach

the

weld

cable

from

the

gun

to

the

Weld

Cable

Terminal

on

the

control/feeder

or

to

the

desired

secondary

cable

from

the

welding

power

source.

2-5.

CHANGING

WIRE

SIZES

(Figure

2-1)

Each

time

the

size

of

the

electrode

wire

being

used

is

changed

it

will

be

necessary

to

change

certain

components

so

that

the

holes

in

these

components

will

permit

proper

movement

of

the

electrode

wire.

The

following

steps

explain

the

proce

dures

necessary

to

adapt

the

gun

to

either

.030, .035,

or

.045

wire.

U

~OTE

~

U

If

the

gun

is

equipped

for

.030

or

035

wire

and

it

is

desired

to

convert

from

one

of

these

wire

sizes

to

the

other,

only

the

contact

tube

(item

2,

Figure

2-1)

will

have

to

be

changed.

However,

if

the

gun

is

equipped

for

.030

or

.036 wire

and

it

is

desired

to

convert

to

.045

wire

(Or

vice

versa),

all

of

the

following

steps

will

haveto

be

performed,

.

OM-1024

Page

1

1.

Cut

off

any

portion

of

the

electrode

wire

which

ex

tends

beyond

the

end

of

the

contact

tube

(2).

2.

Pull

Out

all

of

the

electrode

wire

which

is

in

the

gun

monocoil

and

rewind

it

onto

the

wire

spool.

3.

Pull

off

nozzle

(3)

from

the

gun.

4.

Remove

contact

tube

(2)

from

adapter

(1)

and

remove

adapter

(1)

from

the

gun

body.

5.

Remove

outlet

guide

(5)

from

connector

(8).

6.

Lay

monocoil

casing

(11)

straight

out,

loosen

set

screw

(4),

and

pull

monocoil

(10)

out

of

monocoil

casing

(11).

7.

With

monocoil

casing

(11)

still

straight,

insert

new

monocoil

(10)

intO

monocoil

casing

(11).

8.

Rotate

locking

nut

(7)

onto

connector

(8)

as

far

as

possible.

9.

Rotate

new

outlet

guide

(5)

onto

connector

(8)

as

far

as

possible

and

then

back

off

outlet

guide

(5)

to

a

point

where

the

flat

surface

of

outlet

guide

(5)

will

face

the

securing

screw

on

the

control/feeder

with

the

strain

relief

securing

screw

(9)

being

on

top.

Lock

the

outlet

guide

(5)

in

this

position

by

rotating

locking

nut

(7)

against

outlet

guide

(5).

10.

Push

monocoil

(10)

from

the

opening

in

the

gun

body

so

that

the

monocoil

(10)

is

inserted

as

far

as

possible

into

the

outlet

guide

(10).

Once

fully

inserted,

lock

the

monocoil

in

place

by

tightening

set

screw

(4).

It

is

recommended

that

the

monocoil

casing

(11)

and

monocoil

(10)

both

have

the

inside

blown

out

with



compressed

air

prior

to

assembly.



11

11.

Insert

adapter

(1)

into

gun

body

and

install

new

con

tact

tube

(2)

into

adapter(1).

12.

Push

nozzle

(3)

Onto

gun

body.

Shielding

Gas

5

Outlet

Guide

TB-058

554-2

Figure

2-1.

Gun

Components

1

Weld

Cable

10

4

9

7

8

Gun

Switch

Plug

Connector

Page

2

March

1974

FORM:

OM-1024

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

PARTS

LIST

9

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

lOFt.

l5Ft.

.030

Wire

058

554

058

557

.035

Wire

058

555

058

558

.045

Wire

058556

058559

Effective

with

Style

No.

HE-i

MODEL

MMT-210A

NWSA

CODE

NO.

4579

PUM

Vt3

TC058

554

OM-1024

Page

1

Figure

A



ExplOded

View

of

Gun

Assembly

Item

Factory

No.

Part

No.

Description

Quantity

Model

10

Foot

15 Foot

.8MM

.9MM

1.2MM

.8MM

.9MM

1.2MM

.031

.035

.047

.031

.035 .047

.030

.035

.045

.030

.035

.045

Figure

A

Exploded

View

of

Gun

Assembly

BE

SURE

TO

PROVIDE

STOCK,

MODEL,

AND

STYLE

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

1 1

1

5

1

3

1 1

3

~3

1

~1

1

1 1

1

5

1 1 1

1 1

1

3

3 3

1 1 1

3 3 3

1

058

656

2

058

655

3

058

348

4

054158



5

054242

5

054183

5

054157

6

058292

7

058653

8

605789

9

058

218

10

605758

11

058645

11

058644

12

010497

13

058643

14

057027

15

603887

16

056847

17

601

845

18

058

249

19

602087

20

604

866

21

604

311

22

604874

23

603 886

24

604

525

25

604

523

26

604 524

27

058646

28

058

649

28

058

648

29

605

787

30

602

245

31

058

636

32

602173

33

058

647

34

602088

35

056479

36

056

462

36

056542

37

010 603

38

010

606

39

056

298

39

056

537

40

058563

40

058

564

41

058

652

42

056758

42

056

760

42

056759

42

056761

43

058

654

44

058219

45

605675

46

601

847

1

5

1

3

1

3

1

2

1

2

12

ft.

1

2

1

2

12

ft.

1

TUBE,

head

TUBING,

neophreme

5/8

ID

x

3/32

wail

x

3-1/2

lg

INSULATOR,

nozzle

w/retaining

rings

ADAPTER,

tube

-

contact

TUBE,

contact

TUBE,

contact

TUBE,

contact

NOZZLE,

slip

on

BODY,

head

tube

SCREW,

set

-

steel

socket

hd

10-24

x

1/4

HANDLE,

right

hand

SCREW,

machine

-

steel

md

hd

10-32

x

1

inch

SWITCH,

control

10

ft

(consisting

of)

SWITCH,

control

15

ft

(consisting

of)

CLAMP,

hose

7/32

to

1-3/4

clamp

dia

BASE,

switch

RELIEF,

strain

SCREW,

machine

-

steel

md

hd

2-56

x

1/2

SPRING



NUT,

steel

-

self

locking

hex

8-32



LEVER,

actuating

SCREW,

machine

-

steel

md

hd

8-32

x

1-1/4

SWITCH



GROMMET,

rubber

1/4

ID

3/8

hole

1/16

groove



WASHER,

lock

-

steel

split

No.

2



NUT,

steel

-

hex

2-56



CORD,

portable

No.

18

2

conductor

(order

by

foot)

CAP,

midget

-

twistlock

2P2W

COVER,

seal

-

tite

CABLE,

jumper

GUIDE,

wire

outlet

GUIDE,

wire

outlet

WASHER,

lock

-

steel

internal

tooth

1/2

WASHER,

flat

-

steel

SAE

7/16

NUT,

brass

-

hex

jam

7/16-20

SCREW,

set

-

socket

hd

10-32

x

1/4

CONNECTOR,

monocoil

SCREW,

machine

-

steel

md

hd

10-32

x

1/4

SPRING,

strain

relief

HOSE

ASSEMBLY,

gas

10

ft

(consisting

of)

HOSE

ASSEMBLY,

gas

15

ft

(consisting

of)

NIPPLE,

brass

-

ball

&

barb

stem

1/4

NUT,

brass

-

swivel

5/8-18

RH

.HOSE,gas

HOSE,

gas

CABLE,

conduit

10

ft

CABLE,

conduit

15

ft

CONNECTOR,

gas

-

inlet

CONDUIT,

.190/.191

OD

x

10

ft

10

inches

CONDUIT,

.084

ID

x

.216

OD

x

10

ft

10

inches

CONDUIT,

.059

ID

x

.189

OD

x

15

ft

10

inches

CONDUIT,

.084

ID

x

.216

OD

x

15

ft

10

inches

NUT,

brass

-

hex

jam

1/2-20

HANDLE,

left

hand

PLUG,

snap

in

NUT,

steel

-

self

locking

hex

10-32

1

~1

1 1

1

1

1

2 2

2

~1

1

~1

1 1

1

1

1

~1

1

1 1

2 2 2 2

12

ft.

17

ft.

17

ft.

17

ft.

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

2

1

3

1

1

1 1

1

2

2 2 2

2

1

~1

1

3

~3

3 3 3

OM-1024

Page

2

THE

FOLLOWING

WIRE

GUIDE

KITS

ARE

AVAILABLE

TO

CHANGE

THE

GUN

FROM

ONE

WIRE

SIZE

TO

ANOTHER.

SEE

VIEW

ON

PAGE

1

FOR

IDENTIFICATION

OF

ITEM

NUMBERS.

Item

Factory

No.

Part

No

5

054

242

5

054183

5

054 157

28

058

649

28

058

648

42

056758

42

056760

42

056759

42

056

761

Kit,

Wire

Guide

Description

TUBE,

contact

TUBE,

contact

TUBE,

contact

GUIDE,

wire

outlet

GUIDE,

wire

outlet

CONDUIT,

.1901.191

OD

x

10

ft

10

inches

CONDUIT,

.084

ID

x

.216

OD

x

10

ft

10

inches

CONDUIT,

.059

ID

x

.189

OD

x

15

ft

10

inches

CONDUIT,

.084

ID

x

.216

OD

x

15

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Page

3

Miller MMT-210A Owner's manual

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