OM-1036 169 964A September 1999 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Air-Cooled Gun M-40 Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
SAFETY PRECAUTIONS FOR GMAW GUNS WARNING GMAW WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information found in the wire feeder and welding power source Owner’s Manuals.
SECTION 1 – SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. 1 2 2 WARNING 3 ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Disconnect input power before installing or servicing. CAUTION • Keep away from moving parts. • Keep all panels and covers closed when operating. Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen.
2-1. Duty Cycle CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. wfwarn8.1 8/93 0 Definition 10 Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating.
SECTION 4 – OPERATION READ SAFETY BLOCKS at beginning of manual before proceeding. WARNING 4-1. Operating The Gun 1 Trigger Switch When pressed, energized wire feeds and shielding gas flows. 1 Ref. ST-800 749-A Figure 4-1. Using Gun Switch SECTION 5 – MAINTENANCE & TROUBLESHOOTING READ SAFETY BLOCKS at beginning of manual before proceeding. WARNING 5-1. Maintenance And Troubleshooting Turn Off all power before maintaining.
Table 5-1. Troubleshooting Trouble Remedy Wire does not feed. Section Check contact tip. Check for kinks in gun cable. 5-2 Check gun trigger plug connection at welding power source/wire feeder. 3-1 Check, and if necessary, replace gun trigger switch. 5-3 Check contact tip. 5-2 Check gun trigger plug connection at welding power source/wire feeder. 3-1 Check, and if necessary, replace gun trigger switch. 5-3 Wire feeds unevenly. Check contact tip. Check for kinks in gun cable.
B. Changing Liner CAUTION FLYING METAL CHIPS AND DIRT can cause injury and damage equipment. • Point gun away from people and in a safe direction when blowing out with compressed air. Turn off welding power source/wire feeder. Tools Needed: 7/16 in 7/16 in Head Tube Remove nozzle, contact tip, and adapter. Remove wire outlet guide. Lay gun cable out straight, and remove liner. Blow out gun casing. To Reassemble Gun: Lay gun cable out straight, and insert new liner.
C. Replacing Head Tube Turn off welding power source/wire feeder. 3 1 Do not disturb cable connection between cable connector and connector nut. Loosen cable connector. Remove from vice and turn head tube out by hand. 4 Secure head tube in vice. 2 5 Loosen set screws on body and remove head tube. Slide handle. Remove switch housing. 1/8 in 6 Install new head tube. Tighten set screws to keep head tube in desired position. Install shock washer from existing head tube.
5-3. Switch Replacement Turn off welding power source/wire feeder and, disconnect gun. 1 Switch Housing 2 Screw Remove both mounting screws from switch housing. See Parts List for correct replacement parts. 3 Switch 4 Switch Leads Carefully pull up on leads to remove switch from housing. 5 Switch Lead Connectors Remove switch lead connectors from switch terminals and discard old switch. 4 Push switch lead connectors onto terminals of new switch.
OM-1036 Page 8 2 *Includes Item 17 1 3 4 Figure 6-1.
Item No. Part No. Description Quantity Figure 6-1. M-40 Gun ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 1 2 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22 22 22 22 23 24 25 26 27 28 . . . . . . . . . +169 724 . . . . . . . . . +169 726 . . . . . . . . . +169 727 . . . . . . . . . +169 725 . . . . . . . . . +000 068 . . . . . . . . . +000 069 . . . . . . . . .
Notes
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
