Miller 3868 GUN Owner's manual

Miller
Brand
Miller
Model
3868 GUN
Type
Owner's manual

This manual is also suitable for

December
1976
FORM;
OM-1511A
3868
Gun
.030
Hard
Wire
.035
Hard
Wire
.045
Hard
Wire
5088
Gun
For
Use
With
Vertical
Head
.035Wire
079133
.045Wire
079134
1/16Wire
079135
MODEL
STOCK
NO.
3160
Gun
1689
Gun
With
7
Inch
Extension
3/32Wire
079121
1/8Wire
079122
5/32Wire
079123
3/16Wire
079124
7/32Wire
079125
1/4
Wire
079
126
With
12
Inch
Extension
3/32Wire
079127
1/8
Wire
079
128
5/32Wire
079129
3/16Wire
079130
7/32
Wire
079
131
1/4Wire
079132
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
50
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
c~
MODEL
STOCK
NO.
3700
Gun
3/64
Soft
Wire
1/16
Soft
Wire
3/32
Soft
Wire
.045
Soft
Wire
1/16 Hard/Fluxed
3/32
Hard/Fluxed
7/64
Hard/Fluxed
1/8
Hard/Fluxed
.045
Wire
1/16
Wire
5/64
Wire
3/32
Wire
7/64
Wire
1/8
Wire
079
081
079
082
079
083
079
084
079
085
079
086
079
087
079
088
079
118
079
119
079
120
079
106
079
107
079
108
079
109
079
110
079
111
For
Use
With
.035
Wire
.045
Wire
1/16
Wire
Horizontal
Head
079
136
079
137
079
138
NWSA
CODE
NO.
4579
U.S~.
l~p
1.~
L~
~LLP
~
)
~
~
~p
s~
~ ~ ~
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
3.
All
welding
guns
and
feeder/guns
90
days
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
4.
All
other
Millermatic
Feeders
I
year
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
(30)
days
of
the
date
of
such
failure.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other items
are
sold
subject
to
the
warran-
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREiN
?
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
AND
ANY
IMPLIED
WARRANTY
GUARANTY
OR
REP-
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
RESENTATION
AS
TO
PERFORMANCE,
AND ANY
200
is
limited
to.
six
months
and
on
all
other
engines
to
one
year.
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
therefor
shall
be,
at
Millers
option,
(I)
repair
or
(2)
replace-
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
the
purchase
price
(less
reasonable
depreciation
based
upon
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
ex
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
dures
to
be
followed.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
nat
users
warranty
claims
on
warranted
Equipment
in
the
event
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
?
of
failure
resulting
from
a
defect
within
the
following
periods
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
from
the
date
of
delivery
of
Equipment
to
the
original
user:
WARRANTIES
DO NOT
EXTEND
TO,
AND
NO
RE-
I.
Arc
welders,
power
sources,
and
components
...
1
year
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR
2.
Original
main
power
rectifiers
3
years
RANTIES
TO,
ANY
CONSUMER.
,,
J_
J?
~r5,
~
-
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.
Nomenclature
2
1-5.
Safety
2
SECTION
2
INSTALLATION
2-1.
Model
3700Gun
2
2-2.
Model3lBOGun
3
2-3.
Model
3868Gun
4
2-4.
Model
16890un
5
2-5.
Model
5088
Gun
6
PARTS
LIST
SECTION
1
-
INTRODUCTION
Model
1689
(Submerged-Arc)
Figure
1-1.
Specifications
Model
3700
Rating:
100%
Duty
Cycle,
DCRP
Capacity
Wire
Dia.
Cooling
Method
Net
Weight
Ship
Weight
500
Amp
C02
400
Amp
Argon
Or
~ixes
.045
-
1/8
~
Circulated
Coolant
4lb.
5lb.
500
Amp
CO2
.045
-
1/8
Air
2
lb.
3
lb.
350
Amp
CO2
.030
-
.045
Air
1-1/21b.
2-1/21b.
1689
800
Amp
3/32-1/4
Air
3lb.
41b.
5088
40
Amp
CO2
.035
-
1/16
Air
1-3/4
lb.
2-3/4
lb.
1-1/4
1-1/4
TA-009
021
1-1/8
1
-1/4
Model
3700
(Water-Cooled)
TA-009
023
Model
3160
Model
3868
Ext.
TA-009
022
TA-009
025
TA-009
024
Model
5088
OM-1511
Page
1
*
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.
The
following
definitions
apply
to
CAUTION,
IMPORTANT.
and
NOTE
blocks
found
throughout
this
manual:
~thisheading,ins
tallation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
Create
a
hazard
to
per
sonnel.
I
1TA11
T
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.
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.
1-4.
NOMENCLATURE
Any
reference
to
directions
of
a
unit,
such
as
right
or
left,
are
made
facing
the
front
of
the
unit.
Under
this
heading,
explanatory
statements
will
be~
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
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
shank
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.
~OPT~T
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld
Head
m
If
the
gun
is
equipped
for
use
on
a
vertical
feed
weld~
head
and
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
2-1),
liner
(2),
extension
(3),
and
jam
nut
(4).
2.
Retain
the
weld
cable
terminal
in
its
position
for
future
use.
a.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
b.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
1-5,
SAFETY
I
1-3.
DESCRIPTION
to
installing
any
of
the
gun
5,
ensure
that
the
welding
power
source
and
the
Control/feeder
are
de
energized.
I
2-1.
MODEL3700GUN
~Figure2-1)
Shielding
Gas
Connector
2
.3
~Coolant
Inlet
Connector
-Coolant
Outlet
Connector
Figure
2-1.
Model
3700
Gun
TB-003
622
I
Page
2
c.
Loosen
the
two
ball
joint
adjustment
securing
screws.
d.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
e.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
B.
Shielding
Gas
Connections
Connect
the
shielding
gas
hose
from
the
weld
control
to
the
gun
shielding
gas
connector
(gas
connector
is
illustrated
in
Figure
2-2).
C.
Weld
Cable
Connection
Connect
the
weld
cable
from
the
weld
control
to
the
gun
weld
cable
terminal
(terminal
is
illustrated
in
Figure
2-2).
th
at
the
con
~g
th
of
the
weld
ca
b
le
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.
D.
Outlet
Guide,
Liner,
Extension,
Head
Tube,
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,
extension,
head
tube,
and
contact
tube.
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
2-2).
the
liner
(2),
and
the
extension
(3(.
~edtoSt!sicand~yiftheheadtube(8)is
to
be
replaced.
If
the
head tube
(8)
is
not
to
be
re
placed,
omit
Steps
ic
and
id
and
proceed
directly
to
Step
le.
c.
For
gun
used
with
horizontal
feed
weld
head
only:
Remove
the
gun
from
the
ball
joint.
d.
Remove
the
jam
nut
(4),
weld
cable
terminal,
and
adapter
(5),
thumb-nut
(6),
head
tube
(8),
and
the
two
washers
(7).
e.
Remove
the
nozzle
(10),
if
necessary.
f.
Remove
the
contact
tube
(9).
2.
Assembly
a.
Reverse
Steps
ia
thru
if
(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.
MODEL
3868
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.
Figure
2-3.
Model
3868
Gun
b.
Insert
the
shank
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.
rTANrI
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld Head
If
the
gun
is
equipped
for
use
on
a
vertical
feed
weld
head
and
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
2-3),
liner
(2),
extension
(3),
and
jam
nut
(4).
2.
Retain
the
weld
cable
terminal
in
its
position
for
future
use.
a.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
b.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
c.
Loosen
the
two
ball
joint
adjustment
securing
screws.
d.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
e.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
.3
2
I
S
T6-003
623
U
U
I
U
Page
4
B.
Shielding
Gas
Connection
Contact
Tube.
Securing
Setscrews
Extension
~Contact
Tube
-
ExtensIon
Securing
Nut
Figure
2-4.
Model
1689
Gun
I
U
IMPORTANT
I
U
I
Ensure
that
the
contacting
surfaces
of
the
weld
cable
I
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
1
could
result.
C.
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.
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.
IMPORTANT
I
Ensure
that
the
tip
of
the
gun
extension
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld
Head
rn
Connect
the
shielding
gas
hose
female
connector
from
the
weld
control
to
the
gun
shielding
gas
male
connector
(male
connector
is
illustrated
in
Figure
2-3).
These
connectors
have
right-handed
threading.
C.
Weld
Cable
Connection
Connect
the
weld
cable
from
the
weld
control
to
the
gun
weld
cable
terminal
(terminal
is
illustrated
in
Figure
2-3).
D.
Outlet
Guide,
Liner,
Contact
Tube,
And
Nozzle
In
stallation
Upon
initial
installation,
as
a
result
of
component
wear,
or
when
changing
from
one
welding
wire
size
to
another,
one
or
more
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.
d.
Remove
the
contact
tube
(5).
2.
Assembly
a.
Reverse
Steps
la
thru
id
(Disassembly),
referring
to
Section
2-3,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
if
applicable.
2-4.
MODEL
1689
GUN
(Figure
2-4)
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
shank
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.
If
the
gun
is
equipped
for
use
on
a
vertical
feed
weld
head
and
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
extension.
2.
Retain
the
contact
tube-extension
securing
nut
in
its
position
for
future
use.
I
I
a.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
b.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
c.
Loosen
the
two
ball
joint
adjustment
securing
screws.
d.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
e.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
B.
Weld
Cable
Connection
Connect
the
weld
cable
from
the
weld
control
to
the
gun
weld
cable
terminal
(terminal
is
illustrated
in
Figure
2-4).
TB-003
620
OM-1511
Page
5
2.
Assembly
a.
Reverse
Steps
la
thru
ic
(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
5088
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.
b.
Insert
the
shank
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.
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
I
2.
Horizontal
Feed
Weld
Head
rn
If
the
gun
is
equipped
for
use
on
a
vertical
feed
weld
head
and
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
(2),
extension
(3).
3.
Retain
the
adapter
(4)
in
its
position
for
future
use.
a.
Rotate
the
gun
threaded
female
connector
clockwise
onto
the
ball
joint
threaded
male
connector
as
far
as
possible.
b.
Tighten
the
ball
joint
connector
jam
nut
against
the
gun
connector
to
secure
the
gun
to
the
ball
joint
assembly.
c.
Loosen
the
two
ball
joint
adjustment
securing
screws.
d.
Position
the
gun
as
desired
by
maneuvering
it
within
the
ball
joint.
e.
Tighten
the
two
ball
joint
adjustment
securing
screws
to
secure
the
gun
in
the
desired
position.
B.
Shielding
Gas
Connection
Connect
the
shielding
gas
hose
from
the
weld
control
to
the
gun
shielding
gas
connector
(gas
connector
is
illustrated
in
Figure
2-5).
Figure
2-5.
Model
5088
Gun
C.
Weld
Cable
Connection
Connect
the
weld
cable
from
the
weld
control
to
the
gun
weld
cable
terminal
(terminal
is
illustrated
in
Figure
2-5).
th
at
the
cornac
ng
su~s
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.
D.
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,
the
outlet
guide,
liner
and/or
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.
Loosen
the
liner
securing
setscrew
(item
5,
Figure
2-5).
Remove
the
outlet
guide
and
the
liner
(2).
c.
Remove
the
contact
tube
(6)
by
first
removing
the
contact
tube
securing
nut
(7).
2.
Assembly
a.
Reverse
Steps
la
thru
ic
(Disassembly),
referring
to
Section
2-5,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
if
applicable.
.3
Shieldlng
Gas
Connector
I
Weld
Cable
Terminal
TB-003
621
S
-s
U
I
6
Page
6
December
1976
FORM:
OM-1511A
MODEL
STOCK
NO.
3700
Gun
3/64
Soft
Wire
1/16
Soft
Wire
3/32
Soft
Wire
.045
Soft
Wire
1/16
Hard/Fluxed
3/32
Hard/Fluxed
7/64
Hard/Fluxed
1/8
Hard/Fluxed
3868
Gun
.030
Hard
Wire
.035
Hard
Wire
.045
Hard
Wire
5088
Gun
For
Use
With
Vertical
Head
.035Wire
079133
.045
Wire
079
134
1/16Wire
079135
For
Use
With
Horizontal
Head
.035Wire
079136
.045Wire
079137
1/16Wire
079138
MODEL
STOCK
NO.
3160
Gun
1689
Gun
With
7
Inch
Extension
3/32
Wire
079
121
1/8Wire
079122
5/32Wire
079123
3/16Wire
079124
7/32
Wire
079
125
1/4Wire
079126
With
12
Inch
Extension
3/32Wire
079127
1/8
Wire
079
128
5/32
Wire
079
129
3/16
Wire
079
130
7/32
Wire
079
131
1/4Wire
079132
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
115
11.
079
081
079
082
079
083
079 084
079 085
079
086
079 087
079
088
.045
Wire
1/16~
Wire
5/64
Wire
3/32
Wire
7/64
Wire
1/8
Wire
079
106
079
107
079
108
079
109
079
110
079111
079
118
079
119
079
120
NWSA
CODE
NO.
4579
4
23
Figure
A
Exploded
View
Of
Model
3700
Gun
Er9
11
12
16
15
18
19
TC-039
280-A
1
6
7
8
15
24
15
17
21
20
OM-1
511
Page
1
Item
Factory
No.
Part
No
Figure
A
Descrii
Exploded
View
of
Model
3700
Gun
1
010
867
ELBOW,
brass
-
pipe
90
degree
1/8PT
2
057
540
FITTING,
brass
-
connector
male
3/16
TBGx1/8NPT
3
075
769
BODY
4
075
782
GUIDE,
wire
outlet
4
075
781
GUIDE,
wire
outlet
4
077
286
GUIDE,
wire
outlet
4
075
783
GUIDE,
wire
outlet
4
075
592
EXTENSION
5
075 873
LINER,
nylon
11-7/8
inches
Ig
5
075
778
LINER,
nylon
11-7/8
inches
Ig
5
079 265
LINER,
monocoil
11-7/8
inches
Ig
5
075 860
LINER,
monocoil
11-7/8
inches
Ig
6
075
773
EXTENSION
7
601
883
NUT,
steel
-
hex
jam
5/8-18
8
075774
BUSBAR
9
075 770
EXTENSION,
3
inch
10
075
767
TUBE,
head
11
056
865
FITTING,
hose
-
brass
nut
No.
10
3/8-24
LH
12
056 848
FITTING,
hose
-
brass
barbed
nipple
3/16TBG
BODY,
head
tube
CONNECTOR,
brass
male
3/16TBG
SLEEVE,
brass
-
compression
3/16TBG.
NUT,
brass
-
compression
3/16TBG
TUBE,
coolant-outlet
ADAPTER,
nozzle
TUBE,
contact
3/64
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
.045
wire
TUBE,
contact
1/16
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
1
inch
orifice
x
2-1/2
See
Optional
Equipment
See
Optional
Equipment
075
765
NOZZLE,
5/8
orifice
x
2
075
831
TUBE,
coolant-inlet
2
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
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
1 1
1
1
1
~1
1
1
1
1
1
1
1
1
1
1
1
4
4
4 4 4 4 4
4
4
4
4
4
4
4
1 1
1
1
1
1
1
1
1
1 1 1
1
1
3
1
1
1
1
1
1
1
1
1 1
1
1
Optional
Equipment
Refer
to
Figure
A
on
Page
1
for
identification
of
item
numbers
5
075
861
5
079
266
5
075
862
5
079
264
9
075771
9
075
772
18
079097
19
075763
20
075
764
21
075
765
LINER,
monocoil
14-7/8
inches
Ig
LINER,
monocoil
14-7/8
inches
Ig
LINER,
monocoil
18-7/8
inches
Ig
LINER,
monocoil
18-7/8
inches
Ig
TUBE,
extension
6
inches
Ig
TUBE,
extension
10
inches
Ig
NOZZLE,
1
inch
orifice
x
2-1/2
NOZZLE,
5/8
orifice
x
2-5/16
NOZZLE,
5/8
orifice
x
2-1/8
NOZZLE,
5/8
orifice
x
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
1
1 1
1
1
1
1
1
1
1
1
1
1
1 1
1
1
NOTE:
For
Wire
Guide
Kits
to
change
from
one
size
wire
to
another
size
wire
See
Page
9.
BE
SURE
TO
PROVIDE
STOCK,
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
2
2
2
2
2
2
2 2
2
1 1
1 1
2
2
1
1
1
1
1 1
075
768
079
421
057
591
057 592
075
832
076
146
075
694
075
696
075
697
075
706
075
707
075
708
075
698
075
699
079
097
1
4
4
1
1
3
13
14
15
16
17
18
19
19
19
19
19
19
19
19
20
21
22
23
24
3
3
3
3
3
3
1
1
1
1
OM-1511
Page
2
Figure
B
Exploded
View
Of
Model
3160
Gun
TC-039
276
31
32
36
37
41
Page
3
Item
Factory
No.
Part
No.
Description
Quantity
Model
1.2MM
1.6MM
2.0MM
2.4MM
28MM
3.2MM
.047 .063
.078
.094
.110
.126
.045
1/16
5/64
3/32 7/64
1/8
Figure
B
Exploded
View
of
Model
3160
Gun
31
077
286
31
075
783
32
079163
32
079164
33
075
773
33
075
592
34
601
883
35
075
774
36
075674
37
075671
38
073
779
39
077
264
39
075
687
40
075
754
41
075694
41
075
695
41
075696
41
075697
41
075698
41
075699
42
075
659
32
079
322
32
079
320
32
079319
32
079321
079
323
079
116
079
324
079
117
075
599
GUIDE,
wire
outlet
GUIDE,
wire
outlet
LINER,
monocoil
9-3/16
inches
Ig
LINER,
monocoil
9-3/16
inches
Ig
EXTENSION
EXTENSION
NUT,
steel
-
hex
jam
5/8-18
BUS
BAR
ADAPTER,
extension/head
tube
NUT,
body
WASHER,
flat-
phenolic
5/8
ID
x
1.1100D
x
3/16
TUBE,
head
TUBE,
head
BODY
TUBE,
contact
3/64
wire
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
5/8
orifice
x
2-3/8
Optional
Equipment
Refer
to
Figure
B
on
Page
3
for
identification
of
item
numbers
LINER,
monocoil
11-9/16
inches
Ig
LINER,
monocoil
11-9/16
inches
Ig
LINER,
monocoil
16-9/16
inches
Ig
LINER,
monocoil
16-9/16
inches
Ig
EXTENSION,
3
inches
Ig
EXTENSION,
7
inches
Ig
EXTENSION,
8
inches
Ig
EXTENSION,
12
inches
Ig
NUT,
brass
-
hex
5/8-18
x
1-1/4
Ig
1
1
1
1
1
1
1
1
1 1 1
1
1
1
1
1
1
.1
1
1
2 2
2
2
1 1 1
1
1
1 1
1
3
NOTE:
For
Wire
Guide
Kits
to
change
from
one
size
wire
to
another
size
wire
See
Page
9.
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1
1
1 1
1 1
1
1
1
1
1
1
2 2
1
1
3
3
3
3
3
1
1 1
1
1
1
1
.1
1 1
1
1
1
1 1
1
1
1
1
OM-1511
Page
4
67
~~51
52
53
54
~55
56
Figure
C
Exploded
View
Of
Model
3868
Gun
TC-039
278
64
Page
5
Item
Factory
No.
Part
No.
Figure
C
Exploded
View
of
Model
3868
Gun
Description
Quantity
Model
.8MM
.9MM
1.2MM
.031
.035
.047
.030
.035
.045
53
075
870
57
075
865
58
075
867
63
075 896
64
075
895
65
075
893
66
075 894
67
+075
906
LINER,
nylon
7-11/16
inches
Ig
TUBE,
head
INSULATOR,
head
tube
NOZZLE,
5/8
orifice
x
2-1/2
NOZZLE,
5/8
orifice
x
2-1/4
NOZZLE,
5/8
orifice
x
2-1/4
NOZZLE,
1/2
orifice
x
2-1/4
INSULATOR,
nozzle
Item
Factory
No.
Part
No.
51
077
284
51
075
782
53
075 868
62
075 788
62
075
789
62
075 790
64
075
895
65
075
893
Quantity
Model
.8MM
.9MM
1.2MM
.031
.035 .047
.
.035
.045
~-
L~)
~.D
(0
N
N
N
co
cc
cc
N
N
N.
0
0
0
1 1
3
3
3
BE
SURE TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
51
51
52
53
54
55
56
57
58
59
60
61
62
62
62
63
64
65
66
67
077 284
GUIDE,
wire
outlet
075
782
GUIDE,
wire
outlet
075
773
EXTENSION
075 868
LINER,
nylon
12-3/16
inches
Ig
601
883
NUT,
steel
-
hex
jam
5/8-18
075774
BUS
BAR
075
863
ADAPTER,
extension/head
tube
075864
TUBE,head
075 866
INSULATOR,
head
tube
075 905
NUT,
nozzle
075
890
INSULATOR,
nozzle
075
784
ADAPTER,
contact
tube
075
788
TUBE,
contact
.030
wire
075
789
TUBE,
contact
.035
wire
075 790
TUBE,
contact
.045
wire
See
Optional
Equipment
075
895
NOZZLE,
5/8
orifice
x
2-1/4
075
893
NOZZLE,
1/2
orifice
x
2-1/4
See
Optional
Equipment
075
906
INSULATOR,
nozzle
Optional
Equipment
Refer
to
Figure
C
Page
5
for
identification
of
item
numbers
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
3
3
3
1 1
1
1
1 1
1
1 1 1
1
1
1
1
1 1
1 1
1 1
1
1
1
1
+This
item
is
used
with
075
893
and
075
894
only.
THE
FOLLOWING
WIRE GUIDE
KITS
ARE
AVAILABLE
TO
CHANGE
THE
GUN
FROM
ONE
WIRE
SIZE
TO
ANOTHER.
SEE
FIGURE
C
ON
PAGE
5
FOR
IDENTIFICATION
OF
ITEM
NUMBERS.
Description
Kit,
Wire
Guide
(Use
With
Model
3868
Gun)
GUIDE,
wire
outlet
GUIDE,
wire
outlet
LINER,
nylration
TUBE,
contact
.030
wire
TUBE,
contact
.035
wire
TUBE,
contact
.045
wire
NOZZLE,
5/8
orifice
x
2-1/4
NOZZLE,
1/2
orifice
x
2-1/4
1
1
OM-1511
Page6
Item
Factory
No.
Part
No.
Description
Quantity
Model
2.4MM
3.2MM 4.0MM
4.8MM
5.6MM
6.4MM
.094 .126
.156
.187
.218
.250
3/32
1/8
5/32
3/16 7/32
1/4
Figure
D
Exploded
View
of
Model
1689
Gun
81
079116
81
079117
81
075595
81
075597
82
075
599
83
074
759
84
602009
85
075
600
86
073
303
87
075 602
88
605
369
89
075601
90
078892
91
075
604
91
075605
91
075
606
91
075607
91
075
608
91
075609
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,
spring
1/4
x
1
inch
BLOCK,
blade
&
nozzle
SCREW,
set
-
steel
socket
hd
3/8-16
x
3/8
TUBE,
contact
3/32
wire
TUBE,
contact
1/8
wire
TUBE,
contact
5/32
wire
TUBE,
contact
3/16
wire
TUBE,
contact
7/32
wire
TUBE,
contact
1/4
wire
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
1 1 1
1
1
1
1
1
1
1
1
1 1
1 1
2
2
2
2 2
Figure
D
Exploded
View
Of
Model
1689
Gun
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
7
2
1
2
1
81
.82
83
.84
TC-039
279
85
89
90
91
Item
Factory
No.
Part
No.
Description
Quantity
For
Model
With
Vertical
Head
Horizontal
Head
.9MM
1.2MM 1.6MM
.9MM
1.2MM
1.6MM
.035 .047
.063
.035
.047 .063
.035
.045
1/16
.035
.045
1/16
Figure
E
Exploded
View
of
Model
5088
Gun
Figure
E
Exploded
View
Of
Model
5088
Gun
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
101
077
286
GUIDE,
wire
outlet
1 1
101
075
783
GUIDE,
wire
outlet
1
102
075
773
EXTENSION
1
1 1
103
075 674
ADAPTER,
extension/head
tube
1 1 1 1 1
1
104
076060
TUBE,head
1
1
1 1 1
1
105
602
240
WASHER,
flat
-
steel
1/4
4
4
4
4
4
4
106
601 941
SCREW,
cap
.
steel
hex
hd
1/4-20
x
1-3/4
2 2
2 2 2 2
107
076
043
CLAMP,
insulating
-
cable
1
1 1 1
1 1
108
079
311
LINER,
monocoil
11-5/8
inches
Ig
1
1
108
079312
LINER,monocoil
11-5/8incheslg
1
109
602
177
SCR
EW,
set-steel
socket
hd
1/4-20
x
1/4
1
1
1 1
1
1
110
076056
TUBE,contact
.035
wire
3
3
110
076052
TUBE,contact
.045
wire
3
3
110
076053
TUBE,contact
1/16
wire
3
3
111
076
034
NUT,
steel-hex
9/16-12
special
1 1 1 1
1 1
112
076
043
CLAMP,
insulating
1 1 1
1
1 1
113
602
207
WASHER,
lock
-
steel
split
1/4
2
2 2 2 2
2
114
601
865
NUT,
steel-hex
full
1/4-20
2 2 2
2
2 2
115
076
044
TUBE,
shielded
gas
1 1 1 1
1
1
116
073
433
ADAPTER,
brass-male
1/4NPT
3/16
barb
hose
1
1
1 1 1 1
101
103
104
105
115
107
108
109
114
113
105
112
110
Ill
TC-039
277
OM-1511
Page
8
THE
FOLLOWING
WIRE
GUIDE
KITS
ARE
AVAILABLE
TO
CHANGE
THE
GUN
FROM
ONE
WIRE
SIZE
TO
ANOTHER.
SEE
FIGURE
A
ON
PAGE
1
FOR
IDENTIFICATION
OF
ITEM
NUMBERS.
THE
FOLLOWING
WIRE
GUIDE
KITS
ARE
AVAILABLE
TO
CHANGE
THE
GUN
FROM
SEE
FIGURE
B
ON
PAGE
3
FOR
IDENTIFICATION
OF
ITEM
NUMBERS.
ONE
WIRE
SIZE
TO
ANOTHER~
Item
Factory
No.
Part
No.
31
077286
31
075
783
32
079163
32
079164
33
+075
773
33
++075
592
39
+077
264
39
-i-+075
687
41
075694
41
075695
41
075696
41
075697
41
075698
41
075699
42
075
659
Kit,
Wire
Guide
(Use
With
Model
3160
Gun)
GUIDE,
wire
outlet
GUIDE,
wire
outlet
LINER,
monocoil
9-3/16
inches
Ig
LINER,
monocoil
9-3/16
inches
Ig
EXTENSION
.
EXTENSION
TUBE,
head
TUBE,
head
TUBE,
contact
3/64
wire
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
5/8
orifice
x
2-3/8
+When
changing
from
.045
or
1/16
wires
to
5/64
thru
1/8
wires
it
is
necessary
to
order
these
items
in
addition
to
kit
number.
++When
changing
from
5/64
thru
1/8
to
.045
or
1/16
wires
it
is
necessary
to
order
these
items
in
addition
to
kit
number.
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Factory
No.
Part
No.
Description
Quantity
Model
C)
Kit,
Wire
Guide
(Use
With
Model
3700
Gun)
~
1.2MM
1.6MM
2.4MM
1.2MM
1.6MM
2.4MM
2.8MM 3.2MM
.047 .063
.094
.047
.063
.094
.110 .126
3/64
1/16
3/32
.045
1/16
3/32 7/64
1/8
0
N
C)
C)
C)
C)
C)
C) C)
C)
o
0
0
0
0
0
0
C)
C)
C)
C)
C)
C)
C)
N
N
N
N
N
N
N
o
0
0
0
0 0
0
4
075
782
GUIDE,
wire
outlet
1
4
075
781
GUIDE,
wire
outlet
1 1
4
077
286
GUIDE,
wire
outlet
1
4
075 783
GUIDE,
wire
outlet
4
075592
GUIDE,extension
5
075 873
LINER,
nylon
11-7/8
inches
Ig
1
5
075
778
LINER,
nylon
11-7/8
inches
Ig
1
1
5
079
265
LINER,
monocoil
11-7/8
inches
Ig
1
5
075
860
LINER,
monocoil
11-7/8
inches
Ig
17
075
694
TUBE,
contact
3/64
wire
3
17
075
696
TUBE,
contact
5/64
wire
3
17
075
697
TUBE,
contact
3/32
wire
3
17
075
706
TUBE,
contact
.045
wire
3
17
075
707
TUBE,
contact
1/16
wire
17
075 708
TUBE,
contact
3/32
wire
17
075
698
TUBE,
contact
7/64
wire
17
075
699
TUBE,
contact
1/8
wire
18
079
097
NOZZLE,
1
inch
orifice
x
2-1/2
21
075
765
NOZZLE,
5/8
orifice
x
2
1 1
1
1
1
1
1 1
1
1
3
3
3
3
1
1
1 1
Description
Quantity
Model
1.2MM
1.6MM
2.0MM
2.4MM
2.8MM 3.2MM
.047
.063
.078 .094
.110
.126
.045
1/16
5/64
3/32 7/64
1/8
N
C)
0
N
(0
CD
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
0 0 0
0
+
++ ++
++
++
+
+
++
++
++
++
3
3
3
3
3
3
1
1
1
1
1
Page
9
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Miller 3868 GUN Owner's manual

Miller
Brand
Miller
Model
3868 GUN
Type
Owner's manual
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