Miller Electric MMT-210A User 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
1kJU&J(
M( X
LXYJ(_X
LX
LLXJ&JULX
X
X
LLLX LJ&$
C
b
oT~
OTfl
p
nT~O~t ~fti~T6
~ 8
r8T8T81T6
P
oTo~T~TPT~bt~8TPTooTPTflTPT
C
~
C)
C
~
C)
C
~
CD
C)
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
CD
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)
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
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
U
C
~
U
U
C)
I
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive with
no
other
guarantees
or
C
U
U C)
U
warranties
expressed
or
implied.
c
U
U C)
_______________________________________________________________
Q
Q
p
tQ
Q1.Q..P.J
P
QLRJ..i
P
P
Q9
QLQ
ro~romro
crom

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
1
1
1
1
1
1
1
1
1
5
5
5
1
1
1 1
3
3
1 1
3 ~3
1
~1
1
1
1 1
11
1 1
5
5
111
1 1 1
3
3 3
111
333
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
1
1
1
5
1
1
3
1
3
1
1
1
1
2
1
1
1
1
1
2
2
2
12
ft.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
2
2
12
ft.
1
1
1
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
~1
1 1 1
1
1 1 1
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 2 2
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
11
1
~1
~1
1
1
1
1
1
1
1
1
1
~1
1 1
1
1
1
1 1
~1 1 1
1
~1 111
1
1 1
1
1
~1
111
1
1
1
1
111
11
~1
~.
1
1
~
1
1
1
1
1
1
1
1
1
1
2
1
1
3
1
1
1
1 1
1
2
222
2
1
1 1 1 1
1
~1
11 1
3
~3
333
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 ft
10 inches
Quantity
Model
10
Foot
15 Foot
.8MM
.9MM 1.2MM .8MM .9MM 1.2MM
.031
.035
.047 .031 .035 .047
.
.035
.045
.030
.035 .045
CO
N
U)
~)
C)
C) 0)
0
0
CO
CO
CO CO
N
N
U)
U) U)
U)
U) U)
U)
U)
U)
U)
U) U)
0
0
0
00
0
5
5
1
1
1
1
5
1
5
5
1 1
1 1
5
1
1
BE
SURE
TO PROVIDE
STOCK, MODEL,
AND STYLE NUMBERS WHEN
ORDERING REPLACEMENT PARTS.
Page
3