April
1977
FORM:
OM-1511B
MODEL
STOCK
NO.
3700A
Gun
3/64
Soft
Wire
009
991
1/16
Soft
Wire
009
992
3/32
Soft
Wire
009
993
.045
Soft
Wire
079
084
1/16
Hard/Fluxed
079
085
3/32
Hard/Fluxed
079
086
7/64
Hard/Fluxed
079 087
1/8
Hard/Fluxed
079
088
3868A
Gun
.030
Hard
Wire
009
988
.035
Hard
Wire
009989
.045
Hard
Wire
009
990
5088
Gun
For
Use
With
Vertical
Head
.035Wire
079133
.045Wire
079134
1/16Wire
079135
For
Use With
Horizontal
Head
.035Wire
079136
.045Wire
079137
1/16
Wire
079138
MODEL
STOCK
NO.
3160
Gun
.045
Wire
079
106
1/16Wire
079
107
5/64
Wire
079
108
3/32
Wire
079
109
7/64Wire
079
110
1/8
Wire
079
111
1689
Gun
With
7
Inch
Extension
3/32Wire
079121
1/8Wire
079122
5/32Wire
079123
3/16Wire
079124
7/32
Wire
079
125
1/4Wire
079126
With
12
Inch
Extension
3/32Wire
079127
1/8
Wire
079
128
5/32Wire
079129
3/16Wire
079130
7/32Wire
079131
1/4Wire
079132
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
50
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
(IS
A.
~
1C~
~a~
L
~
L~aP
~aP
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
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
1.
Arc
welders,
power
sources,
and
components
.
..
1
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
1
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
days
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
1
year
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
withi~
thirty
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
~
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRAN1Y
OF
MERCHANTABILITY
OR
OF
FITNESS
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
cx-
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL USERS
AND
FOR
OPERATION
BY
PERSONS
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
)
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
~a
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR-
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
~
...~b
~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Parts
List
For
1689A
Guns
1.6MM
2.4MM 3.2MM
4.0MM
4.8MM
5.6MM
6.4MM
.063
.094
.126 .156
.187
.218
.250
Description
1/16
3/32
1/8
5/32
3/16
7/32
1/4
Exploded
View
of
Model
1689A
Gun
81
079116
81
079117
81
075595
81
075597
82
075599
83
074
759~
84
602009
85
075600
86
073303
87
052
874
88
605 369
89
075601
90
078892
91
075603
91
075604
91
075605
91
075606
91
075607
91
075 608
91
075 609
EXTENSION,
7
inch
or
EXTENSION,
12
inch
EXTENSION,
7 inch
or
EXTENSION,
12
inch
NUT,
brass
-
hex
5/8-18
x
1-1/4
lg
BUS
BAR
SCREW,
cap
-
steel
socket
hd
1/4-20
x
1-1/4
BLOCK,
spring
SPR
ING,
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
TUBE,
contact
7/32
wire
TUBE,
contact
1/4
wire
.
L
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
2
2
2
2 2
2
Item
Factory
No.
Part
No.
Quantity
Model
1
1
1
2
1
1
1
1
2
1
81
1
.82
83
1
1
.84
-
TC-039
279
85
89
90
Exploded
View
Of
Model
1689A
Gun
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-151
1
B
Page
A
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
3700A
Gun
2
2-2.
Model
3l6OGun
3
2
-
3.
Model
3868A
Gun
4
2-4.
Modell689Gun
5
2-5.
Model5O88Gun
6
PARTS
LIST
SECTION
1
-
INTRODUCTION
Model
3700A
Rating:
100%
Duty
Cycle,
DCRP
Capacity
Wire
Dia.
Cooling
Method
Net
Weight
Ship
Weight
500
Amp
CO2
400
Amp
Argon
Or_Mixes
.045-
1/8
Circulated
Coolant
41b.
51b.
3868A
500
Amp
CO2
.045
-
1/8
Air
2
lb.
3
lb.
350
Amp
CO2
.030
-
.045
Air
1-1/2
lb.
2-1/2
lb.
1689
800
Amp
3/32-1/4
Air
3
lb.
4
lb.
5088
400
Amp
CO2
.035
-
1/16
Air
1-3/41b.
2-3/41b.
Model
3700A
(Water-Cooled).
(Submerged-Arc)
Figure
1-1.
Specifications
1
-1/4
1-7/B
1
-1/4
1
-
I/B
TA-009
021
1.1/4
TA-009
023
Model
3160
Model
3868A
TA-009
022
TA-009
025
-
TA-009
024
Model
1689
Model
5088
OM-1511
Page
1
1-1.
GENERAL
1-5.
SAFETY
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,
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:
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
I
I
~L
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.
I
I
-~
I
I~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
I
I
SECTION
2
-
INSTALLATION
-
I
Prior
to
installing
any
of
the
guns,
ensure
that
the
welding
power
source
and
the
control/feeder
are
de
energized.
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.
i
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.
1-2.
RECEIVING-HANDLING
I
I
1-3,
DESCRIPTION
I
I
I
2-1.
MODEL
3700A
GUN
(Figure
2-1)
Shielding
Connector
Figure
2-1.
Model
3700A
Gun
Cable
Terminal
I
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
Connection
Connect
the
shielding
gas
hose
female
connector
from
the
weld
control
to
the
gun
shielding
gas
male
connector
(male
connector
is
illustrated
in
Figure
2-1).
These
connectors
have
right-handed
threading.
C.
Coolant
Connections
Connect
the
coolant
hose
female
connector
from
the
weld
control
to
the
gun
coolant
inlet
male
connector
(male
con
nector
is
illustrated
in
Figure
2-1).
Connect
the
coolant
hose
female
connector
from
the
weld
control
to
the
gun
coolant
outlet
male
connector
(male
connector
is
illustrated
in
Figure
2-1).
These
connectors
have
left-handed
threading.
D.
Weld
Cable
Connect~on
Connect
the
weld
cable
from
the
weld
control
to
the
gun
weld
cable
terminal
(terminal
is
illustrated
in
Figure
2-1
).
th
at
the
co:
surfaces
of
the
weld
cab
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.
E.
Outlet
Guide,
Liner,
Contact
Tube,
And
Nozzle
In
stallation
Upon
initial
instatlation,
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:~6utlet
guide,
liner,
contact
tube,
and
shielding
gas
nozzle.
~fer
to
the
Parts
List
for
the
proper
combination
of
these
com
ponents
for
a
particular
welding
wire
size
and
proceed
with
the
following
instructions:
ion
to
th
ese
com
pon:nt
cha
nges,
o
ther
Co
mpo
nent
changes
in
the
weld head
and
associated
acces
sories
may
be
necessary.
Refer
to
the
individual
instruction
manuals
where
necessary.
Ii
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
2-1)
and
the
liner
(2).
c.
Remove
the
nozzle
(6).
d.
Remove
the
contact
tube
(5).
2.
Assembly
a.
Reverse
Steps
la
through
id
(Disassembly)
referring
to
Section
2-1,
A,
1
for
gun
to
vertical
feed
weld
head
installation,
if
applicable.
Figure
2-2.
Model
3160
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.
~ethatthetipjthejjutletguidedoesnot
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
2-2),
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.
2
.3
4
7
.6
ShIelding
Gac
Connector
TB-039
276
I
I
2-2.
A.
MODEL
3160
GUN
(Figure
2-2)
Gun
To
Weld
Head
Installation
1.
Vertical
Feed
Weld
Head
a.
Loosen
the
two
gun
securing
screws
on
the
weld
head.
OM-1511
Pages
c.
Loosen
the
two
ball
joint
adjusiment
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
~ct
thces
of
the
vi!ld
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,
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).
Figure
2-3.
Model
3868A
Gun
TB-003
623
b.
Insert
the
shank
of
the
gun
into
the
weld
head
gun
hole
until
the
tip
of
the
gun
outlet
guide
is
within
about
i/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.
~RTANT
Ensure
that
the
tip
of the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
Proceed
to
Steps
ic
and
id
only
if
the
head
tube
(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.
2.
Hon
zontal
Feed
Weld
Head
r
r
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.
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
3868A
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.
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.
I
Id
Cable
Terminal
I
7
6
I
U
I
U
I
I
Page
4
B.
Shielding
Gas
Connection
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
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
extension
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld
Head
-
iiu~
r
If
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).
th
at
the
con
faces
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.
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
teed
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.
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.
.
a.
Reverse
Steps
la
thru
ld
(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.
~
Extension
Contact
Tube
-
Extension
Securing
Nut
Weld
Cabie
Terminal
Contact
Tube
Securing
Setscrews
Contact
Tube
TB-003
620
Figure
2-4,
Model
1689
Gun
OM-iSi
1
Page
5
2.
Assembly
a.
Reverse
Steps
Ia
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.
~RTAN~
Ensure
that
the
tip
of
the
gun
outlet
guide
does
not
touch
the
weld
head
drive
rolls.
2.
Horizontal
Feed
Weld
Head
k
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
(31.
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
bell
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
conthc
ng
surfaces
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,
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.
U
I
Weld
Cable
TermInal
TB-003
621
S
I
I
Page
6
April
1977
FORM:
OM-1511B
3868A
Gun
.030
HanI
Wire
009
988
.035
Hard
Wire
009
989
.045
Hard
Wire
009
990
5088
Gun
For
Use
With
Vertical
Head
.035Wire
079133
.045Wire
079134
1/16Wire
079135
For
Use
With
Horizontal
Head
.035
Wire
079
136
.045Wire
079137
1/16Wire
079138
MODEL
STOCK
NO.
3160
Gun
1689
Gun
With
7
Inch
Extension
3/32Wire
079121
1/8Wire
079
122
5/32
Wire
079
123
3/16Wire
079124
7/32Wire
079125
1/4
Wire
079
126
With
12
Inch
Extension
3/32Wire
079127
1/8
Wire
079
128
5/32
Wire
079129
3/16Wire
079130
7/32
Wire
079
131
1/4Wire
079132
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.co.
APPLETON,
WISCONSIN,
USA
54911
U.S
S
MODEL
STOCK
NO.
3700A
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
009
991
009
992
009
993
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
079
111
NWSA
CODE
NO.
4579
4
5
6
7
.8
cr9
11
Figure
A
Exploded
View
Of
Model
3700A
Gun
TC-039
280-B
OM-1
511
Page
1
Item
Factory
No.
Part
No
Figure
A
Description
Exploded
View
of
Model
3700A
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
009452
GUIDE,wire
outlet
4
009454
GUIDE,wireoutlet
4
009453
GUIDE.wireoutlet
4
077286
GUIDE,wire
outlet
4
075
783
GUIDE,
wire
outlet
4
075
952
EXTENSION
5
009
474
LINER,
nylon
11-7/8
inches
Ig
5
009
473
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
075
774
BUS
BAR
9
075
770
EXTENSION,
3
inch
10
075767
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
13
075768
BODY,headtube
14
079
421
CONNECTOR,
brass
male
3/16TBG
15
057
591
SLEEVE,
brass
-
compression
3/16TBG.
16
057
592
NUT,
brass
-
compression
3/16TBG
17
075 832
TUBE,
coolant-outlet
18
076
146
ADAPTER,
nozzle
19
075 694
TUBE,
contact
3/64
wire
19
075
696
TUBE,
contact
5/64
wire
19
075
697
TUBE,
contact
3/32
wire
19
075
706
TUBE,
contact
.045
wire
19
075
707
TUBE,
contact
1/16
wire
19
075 708
TUBE,
contact
3/32
wire
19
075 698
TUBE,
contact
7/64
wire
19
075 699
TUBE,
contact
1/8
wire
20
079
097
NOZZLE,
1
inch
orifice
x
2-1/2
21
See
Optional
Equipment
22
See
Optional
Equipment
23
075
765
NOZZLE,
5/8
orifice
x
2
24
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
2
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 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
3
1
1 1 1
1
1 1 1
1 1
1 1
5
075861
5
079266
5
075862
5
079264
9
075771
9
075 772
18
079097
19
075763
20
075
764
21
075765
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
2
2
2
2
2
2
2
2
2
1 1
1
1
1
4
4
1
3
3
3
3
3
3
Optional
Equipment
Refer
to
Figure
A
on
Page
1
for
identification
of
item
numbers
NOTE:
For
Wire
Guide
Kits
to
change
from
one
size
wire
to
another
size
wire
See
Page
11.
BE
SURE
TO
PROVIDE
STOCK,
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1511
Page
2
-o
03
(0
CD
(4
1,
cc
C
CD
m
0
a
CD
0.
CD
0
-4
CA)
C)
C
-4
9
0
0
CD
-J
a
a
a
-~
C
/
/
/
/
(4
(4
C)
Ui
a
Item
Factory
No.
Part
No.
Description
Figure
B
Exploded
View
of
Model
3160
Gun
31
077
286
31
075 783
32
07,9
163
32
079164
33
075
773
33
075
592
34
601
883
35
075
774
36
075 674
37
075671
38
073779
39
077
264
39
075
687
40 075
754
41
075694
41
075695
41
075696
41
075 697
41
075698
41
075699
42
075
659
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
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
3
3
3
3
1
1
1 1
1
1
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
1g..
LINER,
monocoil
16-9/16
inches
Ig
LINER,
monocoil
16-9/16
inches
1g.
EXTENSION,
3
inches
Ig
EXTENSION,
7
inches
Ig
EXTENSION,
8
inches
Ig
EXTENSION,
12
inches
Ig
NUT,
brass-hex
5/8-18x
1-1/41g....
1
1
1
1
1
1
1
NOTE:
For
Wire
Guide
Kits
to
change
from
one
size
wire
to
another
size
wire
See
Page
11.
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
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
1
1
1
1
1
1
1
2
3
32
079
322
32
079
320
32
079319:
32
079321
079
323
079
116
079
324
079
117
075 599
1 1 1 1
1
1 1
1
OM-1
511
Page
4
67
51
Figure
C
Exploded
View
Of
Model
3868A
Gun
TC-039
278-A
58
59
66
64
Page
5
Item
Factory
No.
Part
No.
51
51
52
53
53
1
54
55
56
57
58
59
60
61
62
62
62
63
64
65
66
67
Description
Quantity
Model
.8MM
.9MM
1.2MM
.031
.035
.047
.030
.035
.045
1
1
1
1
1
3
1
1
1
1
1
1
1
1 1
1 1
1
1
1
1
1
1
3
3
53
075
870
LINER,
nylon
7-11/16
inches
Ig
57
075 865
TUBE,
head
58
075
867
INSULATOR,
head
tube
63
075
896
NOZZLE,
5/8
orifice
x
2-1/2
64
075
895
NOZZLE,
5/8
orifice
x
2-1/4
65
075
893
NOZZLE,
5/8
orifice
x
2-1/4
66
075
894
NOZZLE,
1/2
orifice
x
2-1/4
67
+075
906
INSULATOR,
nozzle
+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.
Item
Factory
No.
Part
No
51
009455
51
009456
53
009475
53
009
476
62
075
788
62
075 789
62
075
790
64
075
895
65
075893
Kit,
Wire
Guide
(Use
With
Model
3868A
Gun)
GUIDE,
wire
outlet
GUIDE,
wire
outlet
LINER,
nylon
12-3/16
inches
Ig
LINER,
nylon
12-3/16
Ig
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
Quantity
Model
.8MM
.9MM
1.2MM
.031
.035
.047
.030
.035 .045
~
L~)
~
w
~D
w
N
N
N
N
N
N
0
0
0
1
1
Figure
C
Exploded
View
of
Model
3868A
Gun
1
1
1
009
455
GUIDE,
wire
outlet
009
456
GUIDE,
wire
outlet
075
773
EXTENSION
009475
LINER,nylon
12-3/l6incheslg
.........
009476!
LINER,nylon
12-3/l6incheslg
.
601
883
NUT,
steel
-
hex
jam
5/8-18
075774
BUS
BAR
075
863
ADAPTER,
extension/head
tube
075
864
TUBE,
head
075 866
INSULATOR,
head
tube
075 905
NUT,
nozzle
075
890
INSULATOR,
nozzle
075
784
ADAPTER,
contact
tube
075788
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
Description
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1 1
3
3
1 1
1
1
3
OM-1511
Page~6
Item
Factory
No.
Part
No.
Descriotion
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
0
Exploded
View
of
Model
1689
Gun
81
079116
81
079117
81
075
595
81
075
597
82
075
599
83
074759
84
602 009
85
075600
86
073
303
87
075
602
88
605 369
89
075601
90
078892
91
075604
91
075
605
91
075606
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
1
1
2
1
1
1
1
2
1
1
-84
Tc-039
279
85
86
87
89
~90
91
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