JA21

Miller JA21, GA-40C Owner's manual

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July

1985

FORM:

OM-1535

Effective

With

Style

No.

JA-21

MODEL

GA-40C

F11LE

COPY

RETURN

TO

FOLDER

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

Co.

718

S.

BOUNDS

ST,

P.O.

Box

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

35

CENTS

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

IMPORTANT

Read

and

understand

the

entire

contents

of

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

on

the

safety

material

throughout

both

manuals,

before

installing,

operating,

or

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

by

persons

trained

and

experienced

in

the

safe

operation

of

welding

equipment.

Do

not

allow

untrained

persons

to

install,

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

25.

1985

This

warranty

supersedes

all

previous

MILLER

warranties

and

is

ex

clusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY

-

Subject

to

the

terms

and

condi-

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

tions

hereof,

Miller Electric

Mfg.

Co.,

Appleton,

Wisconsin

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

4

warrants

to

its

Distributor/Dealer

that

all

new

and unused

therefore

shall

be,

at

Millers

option

(1)

repair

or

(2)

replacement

Equipment

furnished

by

Miller

is

free

from

defect

in

workman-

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

ship

and

material

as

of

the

time

and

place

of

delivery

by

Miller.

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

No

warranty

is

made

by

Miller

with

respect

to

engines,

trade

Miller

service

station

or

(4)

payment

of

or

credit

for

the

purchase

accessories

or

other

items

manufactured

by

others.

Such

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

engines,

trade

accessories

and

other

items

are

sold

subject

to

return

of

the

goods

at

Customers

risk

and

expense.

MILLERs

?

the

warranties

of

their

respective

manufacturers,

if

any

.

All

option

of

repair

or

replacement

will

be

F.O.B.,

Factory,

at

engines

are

warranted

by

their

manufacturer

for

one

year

from

Appleton,

Wisconsin,

or

F.O.B.,

at

a

MILLER

authorized

service

date

of

original

purchase,

except

Tecumseh

engines

which

facility,

therefore,

no

compensation

for

transportation

costs

of

have

a

two

year

warranty.

any

kind

will

be

allowed.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

warranty

Except

as

specified

below,

Millers

warranty

does

not

apply

claim

procedures

to

be

followed.

to

components

having

normal

useful

life

of

less

than

one

Ii)

year,

such

as

spot

welder

tips,

relay

and

contactor

points,



MILLERMATIC

parts

that

come

in

contact

with

the

welding

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

,j)

wire

including

nozzles

and

nozzle

insulators

where

failure

does

ANY

IMPLIED

WARRANTY,

GUARANTY

OR

REPRESENTA-

k~

r~

not

result

from

defect

in

workmanship

or

material.

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

Miller

shall

be

required

to

honor

warranty

claims

on

war-

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

INCLUDING

~,

~

within

the

following

periods

from

the

date

of

delivery

of

Equip-

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

OF

~

ment

to

the

original

user:

FITNESS

FOR

PARTICULAR

PURPOSE,

WiTH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EX

1:

~rn:I1dr:~n=errsr:~:r:nd

~

.~.

~

CLUDED

AND

DISCLAIMED

BY

MILLER.

3.

A~

welding

guns,

feeder/guns

and

plasma

torches...

90

days

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

4.

All

other

Millermatic

Feeders

1

year

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

5.

Replacement

or

repair

parts,

exclusive

of

labor..

60

days

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

6.

Batteries

6

months

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

provided

that

Miller

is

notified

in

writing

within

thirty

(30)

days

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

of

the

date

of

such

failure.

CONSUMER

USE.

MILLERS

WARRANTIES

DO

NOT

EXTEND

~

MILLERS

WARRANTIES

ANY

CONSUMER.

EXTEND

SECTION

1

-

INTRODUCTION

Ampere

Rating

60%

Duty

Cycle

dcrp

Wire

.

Diameter



~

.035

thru

5/64

in.

(0.9

thru

2.0

mm)

Hard

Cable

And

Hose

Length

Cooling

Method

Weight

Net

Ship

400

Amperes

With

C02

10

ft.

(3

m)

Air

8-1/4

lbs.

(3.8

kg)

9-3/4

lbs.

(4.4

kg)

15

ft.

(4.6

m)

Air

11-3/4

lbs.

(5.3~

kg)

13-1/4

lbs.

(6

kg)

Figure

1

-

1.

Specifications

1

-

1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

B.

Safety

G

-

Gun

A

-

Air

Cooled

40

-

Ampere

Rating:

400

Amperes

C

-

Curved

Head

Tube

SECTION

2

-

INSTALLATION

ELECTRIC

SHOCK

can

kill.



Do

not

touch

five

electrical

parts.



Disconnect

input

power

and

employ

lockout/tagging

procedures

before

instalfing

gun.

Lockout/tagging

procedures

consist

of

padlocking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnecting

device.

2

-

1.

GUN/FEEDER

CONNECTOR

INSTALLA

TION

(Figure

4-1)

IMPORTANT

the

gun

assembly.

The

outlet

guide

is

provided

as

part

of

1.

Loosen

the

gun/feeder

connector

securing

knob

on

the

wire

drive

assembly.

IMPORTANT

_____________

The

outlet

guide

should

be

positioned

as

close

as

possible

to

the

drive

rolls

without

touching

them.

This

gives

the

wire

maximum

column

strength

thus

ellminating

waves.

2.

Insert

the

gun/feeder

connector

into

the

wire

drive

assembly.

CAUTION

IMPORTANT

Information

presented

in

this

manual,

and

on

various

labels,

tags,

and

plates

on

the

unit

pertains

to

equip

ment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

be

read,

understood,

and

followed

for

the

safe

and

effective

use

of

this

equip

ment.

The

installation,

operation,

maintenance,

and

troubleshooting

of

arc

welding

equipment

require

prac

tices

and

procedures

which

ensure

personal

safety

and

the

safety

of

others.

Therefore,

this

equipment

is

to

be

installed,

operated,

and

maintained

only

by

qualified

persons

in

accordance

with

this

manual

and

all

ap

plicable

codes

such

as,

but

not

limited

to,

those

listed

at

the

end

of

Section

1

-

Safety

Rules

For

Operation

Of

Arc

Welding

Power

Source

in

the

welding

power

source

Owners

Manual.

Safety

instructions

specifically

pertaining

to

this

unit

ap

pear

throughout

this

manual

highlighted

by

the

signal

words

and

___________

which

identify

different

levels

of

hazard.

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

serious

personal

injury

or

loss

of

life.

___________

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

minor

personal

injury

or

damage

to

this

equipment.

A

third

signal

word,

______________,

highlights

instruc

tions

which

need

special

emphasis

to

obtain

the

most

efficient

operation

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

will

be

furnished

by

the

manufacturer

on

re

quest

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

it

is

essential

that

Model

Description

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

1

-

3.

DESCRIPTION

-

This

gun

is

specifically

for

use

with

the

Gas

Metal-Arc

Welding

process.

The

alpha

numeric

designation

refers

to

the

following:

WARNING

CAUTION

WARNING

WARNING

OM-1

535

Page

1

3.

Tighten

the

gun/feeder

connector

securing

knob.

2

-

2.

GUN

SWITCH

CONNECTION

(Figure

4-1)

-

Align

the

key

on

the

gun

switch

connector

with

the

keyway

on

the

Switch

Control

receptacle;

insert

the

connector

and

rotate

the

threaded

collar

clockwise.

2

-3.

REPOSITIONING

GUN

SWITCH

(Figure

4-1)

-

The

gun

is

shipped

with

the

gun

switch

position

ed

as

illustrated

in

Figure

4-1.

The

gun

switch

can

be

repositioned

on

top

of

the

gun

handle

by

following

the

procedure

outlined

in

Steps

1-9.

1.

Loosen

head

tube

setscrew

in

gun

handle.

2.

Remove

liner

setscrew.

3.

Remove

pin

and

locking

ring

holding

handle

halves

together.

4.

Separate

two

halves

of

gun

handle.

5.

Rotate

head

tube

1800.

Ensure

that

machined

depressions

in

head

tube

are

lined

up

with

hole

for

setscrew

and

gun

cavities.

ii~i~iit~i~

Ensure

that

the

switch

leads

do

not

become

twisted

when

the

head

tube

is

rotated.

6.

Replace

liner

setscrew

in

opposite

side

of

handle.

7.

Join

handle

halves

together

and

rotate

locking

ring.

8.

Insert

pin

through

handle

halves

and

switch

lever.

Ensure

that

switch

spring

is

properly

posi

tioned

in

handle.

9.

Tighten

head

tube

setscrew.

SECTION

3

-

SEQUENCE

OF

OPERATION

3

-

1.

DUTY

CYCLE

-

The

duty

cycle

of

a

welding

gun

is

the

percentage

of

a

ten

minute

period

that

a

gun

can

be

operated

at

a

given

load.

This

gun

is

rated

at

60%

duty

cycle

using

C02

shielding

gas.

This

means

that

the

gun

can

be

operated

six

minutes

out

of

every

ten

with

the

CO2

gas

shielding.

The

remaining

four

minutes

the

gun

should

be

idle

to

permit

proper

cooling.

~

EXCEEDING

THE

RATED

AMPERAGE

WITH

CO2

OR

FAILING

TO

REDUCE

THE

WELDING

AMPERAGE

OR

DUTY

CYCLE

WHEN

USING

A

MIXED

SHIELDING

GAS

can

result

in

damage

to

the

gun.



Do

not

exceed

rated

amperage

when

using

CO2.



Operate

at

30%

duty

cycle

when

using

mixed

shielding

gases.

3

-2.

GAS

METAL-ARC

WELDING

1.

Ensure

that

proper

electrical

connections

have

been

made

to

the

welding

power

source

and

the

wire

feeder.

ELECTRIC

SHOCK

can

kill.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

touch

five

electrical

parts.



Do

not

point

gun

toward

any

part

of

the

body,

or

other

personnel,

or

any

conducting

surface

when

threading

welding

wire.

The

welding

wire

and

all

metal

parts

in

contact

with

it

are

energized

when

gun

trigger

is

depressed.

IMPORTANT

______________

When

installing

new

equipment,

or

after

prolonged

shutdown,

allow

shielding

gas

to

flow

continuously

for

at

least

one

minute

prior

to

welding

to

purge

the

shielding

gas

line.

To

avoid

wasting

wire

while

purging,

loosen

pressure

adjustment

knob

on

drive

assembly,

and

pivot

free

from

cover.

8.

Press

Purge

button

on

the

wire

feeder

(if

ap

plicable)

or

the

gun

switch

to

purge

the

gas

line.

9.

Close

drive

roll

cover

and

adjust

tension

(see

ap

propriate

Owners

Manual).

2.

Ensure

that

the

proper

shielding

gas

is

connected

to

the

shielding

gas

valve.

3.

Ensure

that

the

welding

wire

has

been

properly

threaded

and

that

correct

initial

tensions

have

been

set

on

the

drive

rolls

(refer

to

the

ap

propriate

Owners

Manual).

4.

Turn

on

the

shielding

gas

supply.

5.

Place

the

wire

feed

control(s)

in

the

required

position

for

the

welding

setup.

6.

Place

the

controls

on

the

welding

power

source,

in

the

required

position

for

the

welding

setup

(refer

to

welding

power

source

Owners

Manual).

7.

Energize

the

welding

power

source

and

the

wire

feeder

(refer

to

the

respective

Owners

Manuals).

10.

Actuate

the

gun

switch

to

run

the

wire

out

beyond

the

end

of

the

gas

nozzle.

Cut

the

wire

off

so

it

sticks

out

approximately

1/4

to

3/8

in.

(6.4

to

9.5

mm)

from

the

nozzle.

11.

Set

the

Wire

Speed

control

slightly

in

excess

of

anticipated

wire

speed.

WARNING

_________

ARC

RAYS,

SPARKS,

AND

HOT

SURFACES

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

correct

eye,

ear,

and

body

protection.

FUMES

AND

GASES

can

seriously

harm

your

health.



Use

enough

ventilation

to

keep

fumes

and

gases

from

the

breathing

zone.

See

Section

1

-

Safety

Rules

For

Operation

Of

Arc

Welding

Power

Source

in

welding

power

source

Owners

Manual

for

basic

welding

safety

information.

OM-1

535

Page

2

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Do

not

touch

welding

wire

or

any

metal

part

in

contact

with

it

while

welding.

Welding

wire

and

all

metal

parts

in

contact

with

it

carry

weld

current

when

the

gun

switch

is

depressed.

12.

Hold

the

end

of

the

gas

nozzle

approximately

1/2

in.

(12.7

mm)

from

the

workpiece.

13.

Press

the

gun

switch.

Gas

will

start

to

flow,

wire

will

start

to

feed,

and

the

arc

will

be

established.

If

wire

slippage

is

noticed,

tighten

drive

roll

pressure

adjustment

1/4

turn

at

a

time

until

slip

page

stops.

Do

not

overtighten.

14.

After

the

controls

on

the

welding

power

source

and

the

wire

feeder

(if

applicable)

have

been

ad

justed

for

normal

operation,

welding

power

source

(and

wire

feeder)

will

function

automatically

whenever

the

gun

switch

is

depressed.

Releasing

the

switch

will

extinguish

the

arc

and

cause

wire

feed

and

gas

flow

to

stop.

3

-

3.

SHUTFING

DOWN

1.

Stop

welding.

2.

Turn

off

welding

power

source

and

wire

feeder.

3.

Turn

off

the

shielding

gas

at

the

source.

L~~U~E

HIGH

CONCENTRATION

OF

SHIELDING

GAS

can

harm

health

or

kill.

S

Shut

off

gas

supply

when

not

in

use.

SECTION

4

-

MAINTENANCE

4

-

1.

INSPECTION

AND

UPKEEP

-

Usage

and

shop

conditions

will

determine

frequency

and

type

of

maintenance

required.

1.

Inspect

gun

for

broken

areas,

cracks

and

loose

parts;

tighten,

repair

and

replace

as

required.

2.

Carefully

remove

any

weld

spatter

or

foreign

matter

which

may

accumulate

around

the

nozzle

orifice.

3.

Remove

any

accumulation

around

the

switch.

4.

Repair

or

replace

as

required

all

hose

and

cabl

ing;

give

particular

attention

to

frayed

and

crack

ed

insulation

and

areas

where

it

enters

equip

ment.

5.

Remove

grease

and

grime

from

components;

moisture

from

electrical

parts

and

cables.

CAUTION:

FLYING

DIRT

AND

METAL

PAR

TICLES

can

injure

personnel

and

damage

equip-

Point

gun

liner

only

in

a

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

6.

Blow

out

gun

casing

or

liner

with

compressed

air

whenever

the

wire

or

liner

is

removed.

4

-

2.

CONTACT

TUBE

REPLACEMENT

(Figure

4-1)

1.

Remove

nozzle.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

end

of

contact

tube.

3.

Remove

contact

tube

and

replace

with

new

con-

tact

tube.

4.

Replace

nozzle

and

resume

operation.

4

-

3.

CHANGING

WIRE

SIZES

(Figure

4-1)

WARNING

_________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

disconnect

from

line

power

employing

lockout/tagging

pro

cedures

before

internally

inspecting

or

servicing.

Lockout/tagging

procedures

consist

of

padlocking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnecting

device.

When

changing

the

gun

from

.035

or

.045

in.

(0.9

or

1.1

mm)

wire

to

1/16

or

5/64

in.

(1.6

or

2.0

mm)

wire

or

vice

versa,

it

is

necessary

to

change

the

contact

tube,

contact

tube

adapter,

liner,

and

wire

guides.

(For

inlel

wire

guide

installation,

refer

to

the

appropriate

welding

power

source

or

wire

feeder

Owners

Manual.)

1.

Remove

nozzle.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

end

of

contact

tube.

3.

Remove

contact

tube.

4.

Retract

wire

onto

wire

spool

(see

wire

feeder

Owners

Manual).

5.

Disconnect

gun

assembly

from

wire

feeder.

6.

Remove

outlet

wire

guide.

7.

Loosen

liner

setscrew.

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

five

electrical

parts.



Disconnect

gun

from

wire

feeder

before

internally

inspecting

or

servicing.

HOT

SURFACES

can

cause

severe

burns.



Al/ow

cooling

period

before

servicing.

ment.

S

OM-1535

Page

3

8.

Remove

contact

tube

adapter

(if

applicable).

9.

Lay

cable

assembly

out

flat

and

straight

(no

coils

in

the

cable/conduit).

10.

Pull

out

liner

from

gun/feeder

connector

end

of

gun

assembly

(if

applicable).

________

FLYING

DIRT

AND

METAL

PAR

TICLES

can

injure

personnel

and

damage

equip

ment.



Point

gun

liner

only

in

a

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

11.

Blow

out

gun

casing

or

liner

with

compressed

air

whenever

the

wire

or

liner

is

removed.

12.

Loosen

collar

setscrew

and

remove

collar

and

0-ring

from

existing

liner

(if

applicable).

13.

Slide

the

0-ring

onto

the

end

of

sleeving

on

the

new

liner.

Position

collar

against

the

liner

sleev

ing

so

that

1-1/8

in.

(28.6

mm)

of

the

liner

pro

trudes

beyond

collar,

and

secure

collar

with

setscrew

(if

applicable).

Outlet

Wire

Guide



Collar

TC-044

406-A

CAUTION

CAUTION

14.

Insert

new

liner

into

gun/feeder

connector

end

of

gun

assembly

(if

applicable).

15.

Install

new

outlet

wire

guide.

16.

Cut

liner

off

so

it

sticks

out

1/4

in.

(6.4

mm)

from

the

end

of

the

head

tube

(if

applicable).

17.

Install

new

contact

tube

adapter.

18.

Install

new

contact

tube.

_________

OVERTIGHTENING

LINER

SETSCREW

will

damage

liner.



Do

not

overtighten

liner

setscrew.

19.

Tighten

liner

setscrew

in

gun

handle

to

lock

the

liner

in

place

(if

applicable).

20.

Replace

nozzle.

21.

Make

gun

connections

as

instructed

in

Sections

2-1

and

2-2.

22.

Thread

new

size

electrode

wire.

Head

Tube.

Nozzle

Contact

Tube

Contact

Tube

Adaptor

Leaf

Switch

Switch

Spring

Handle.

Bottom

Half

Handle.

Top

Half

Monocoil

Liner

Strain

Relief

0-Ring

Gun/Feeder

Connector

Figure

4

-

1.

Gun

Components

OM-1535

Page4

1.

Remove

nozzle.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

end

of

contact

tube.

3.

Remove

contact

tube.

4.

Retract

wire

onto

wire

spool

(see

wire

feeder

Owners

Manual).

5.

Disconnect

gun

assembly

from

wire

feeder.

6.

Remove

outlet

wire

guide.

7.

Loosen

liner

setscrew.

8.

Remove

contact

tube

adapter.

9.

Lay

cable

assembly

out

flat

and

straight

(no

coils

in

the

cable/conduit).

10.

Pulloutthelinerfrom

gun/feeder

connector

end

of

gun

assembly.

FLYING

DIRT

AND

METAL

PAR-

CAUTION:

13.

With

switch

spring

properly

positioned

in

guii

handle

(see

Figure

4-1),

insert

pin

through

gun

handle

halves

and

gun

switch.

14.

Tighten

the

head

tube

setscrew.

OVERTIGHTENING

LINER

SETSCREW

will

damage

liner.



Do

not

overtighten

finer

setscrew.

15.

Replace

liner

setscrew

and

tighten.

16.

Replace

nozzle

locking

nut,

insulator,

contact

tube

adapter,

and

nozzle.

4

-

5.

INSTALLING

REPLACEMENT

LINER

(Figure

4-2)

_________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

five

electrical

parts.



Disconnect

input

power

to

we/ding

power

source

and

employ

lockout/tagging

procedures

before

internally

inspecting

or

servicing.

Lockout/tagging

procedures

consist

of

padlocking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnecting

device.

WARNING

L~~U~L

ELECTRIC

SHOCK

can

kill;

WELDING

WIRE

can

cause

puncture

wounds;

ENERGIZED

WELDING

WIRE

may

cause

arcing

when

touching

conductive

objects.



Do

not

touch

live

electrical

parts.



Do

not

point

gun

toward

any

part

of

the

body,

other

personnei.

or

any

conductive

surface

when

threading

welding

wire.



Use

cold

wire

JOG

button,

if

available,

to

thread

wire.

The

welding

wire

and

all

metal

parts

in

contact

with

it

are

energized

when

the

gun

switch

is

pressed.

23.

Resume

operation.

4

-

4.

CHANGING

THE

HEAD

TUBE

(Figure

4-1)

1.

Disconnect

gun

assembly

from

wire

feeder.

2.

Remove

the

nozzle,

contact

tube

adapter,

in

sulator,

and

nozzle

retaining

nut

from

head

tube.

3.

Remove

liner

setscrew.

4.

Loosen

head

tube

setscrew.

5.

Remove

pin

and

locking

ring

holding

the

gun

handle

halves

together.

6.

Separate

the

gun

handle

halves.

7.

Remove

head

tube

from

cable

connector.

8.

Remove

acrylic

glass

tubing

from

head

tube.

9.

Install

acrylic

glass

tubing

on

new

head

tube.

10.

Install

new

head

tube

on

cable

connector.

______________

If

replacing

an

800

head

tube

with

a

600 head

tube

or

a

straight

head

tube,

cut

the

existing

liner

off

so

it

sticks

out

1/4

in.

(6.4

mm)

from

the

end

of

the

head

tube.

If

replacing

a

600

or

a

straight

head

tube

with

an

800

head

tube,

remove

the

outlet

wire

guide

from

the

gun/feeder

connector

and

remove

the

finer.

Prepare

and

install

the

finer

as

instructed

in

Section

4-3,

Steps

11-14.

Reinstall

the

outlet

wire

guide.

Cut

the

liner

off

so

it

sticks

out

1/4

in.

(6.4

mm)

from

the

end

of

the

head

tube.

11.

Position

cable/conduit

and

head

tube

in

bottom

half

of

gun

handle

with

acrylic

glass

tube

on

top

of

the

leaf

switch

and

the

cable

strain

relief

fitted

into

the

appropriate

groove.

______________

Ensure

that

the

leaf

switch

is

properly

positioned

in

bottom

haff

of

gun

handle

as

illustrated

in

Figure

4-1,

and

the

machined

depression

in

the

head

tube

is

lined

up

with hole

for

the

head

tube

setscrew.

12.

Join

the

gun

handle

halves

together

and

rotate

the

locking

ring.

IMPORTANT

IMPORTANT

CAUTION

TICLES

can

injure

personnel

and

damage

equip

ment.



Point

gun

liner

only

in

a

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

11.

Blow

Out

gun

casing

or

liner

with

compressed

air

whenever

the

wire

or

liner

is

removed.

12.

Loosen

collar

setscrew

and

remove

collar

anid

0-ring

from

the

existing

liner

if

applicable.

OM-1535

Fage5

13.

Slide

the

0-ring

onto

the

end

of

sleeving

on

the

new

liner.

Position

collar

against

the

liner

sleev

ing

so

that

1-1/8

in.

(28.6

mm)

of

the

liner

pro

trudes

beyond

collar,

and

secure

collar

with

setscrew

if

applicable.

14.

Insert

new

liner

into

the

gun/feeder

connector

end

of

the

gun

assembly.

15.

Install

appropriate

outlet

wire

guide.

CAUTION

________

OVERTIGHTENING

LINER

SETSCREW

will

damage

liner.



Do

not

overtighten

finer

setscrew.

16.

Tighten

liner

setscrew.

17.

Cut

liner

off

so

it

sticks

out

1/4

in.

(6.3

mm)

from

the

end

of

the

head

tube.

18.

Reinstall

appropriate

contact

tube

adapter,

con

tact

tube,

and

nozzle.

19.

Thread

welding

wire

and

resume

operation.

Liner



Setscrew

Outlet

Collar

~

Wire

0-Ring

~

~

Guide

Gun/Feeder

Connector

TC083

963

Nozzle

6~Contact

Tube

Tube

Adapter

Figure

4

-

2.

Liner

Replacement

OM-1535

Page6

PARTS

LIST

November

1984

FORM:

OM-1535

Effective

With

Style

No.

JA-21

1

37

Figure

A

-

Exploded

View

Of

GA-40C

Gun

TC-049

927-B

2

5

36

9

10

11

21

20

11

18

19

Includes

Items

~~

thru

30

fl-i

27

OM-l53SPagol

Figure

A

Exploded

View

Of

GA-40C

Gun

Description

Quantity

1

047

957

2

054

183

2

054

157

2

047

566

2

047

565

3

094

985

3

094 987

4

094986

5

047603

6

081

957

7

601

869

8

089

400

9

049 737

10

059294

11

049313

12

047867

13

049872

14

079878

15

079535

16

048834

17

604525

18

081

909

19

091

602

20

047 574

21

079 974

22

047

555

22

047 556

23

049312

24

081

959

25

049

876

26

047

564

27

t083

891

28

079

975

29

049

307

30

081

959

27

t083

897

28

079

975

29

047

557

30

081

959

31

049

298

32

047

572

32

047

573

33

059

293

34

602173

35

047

575

36

049 854

37

046115

NOZZLE,

screw

type

1/2

orifice

x

2-3/4

NOZZLE,

screw

type

13/16

orifice

x

2-3/4

NOZZLE,

spot

-

flat

1-1/16

ID

x

3-19/32

NOZZLE,

spot

-

inside

corner

1-1/16

ID

x

3-19/32

2

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

2ft

2

1

1

2

1

1

3

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Item

No.

Part

No.

NOZZLE,

screw

type

5/8

orifice

x

2-3/4

TUBE,

contact

.035

wire

TUBE,

contact

.045

wire

TUBE,

contact

1/16

wire

TUBE,

contact

5/64

wire

ADAPTER,

tube

-

contact

.035-.045

wire

ADAPTER,

tube

-

contact

1/16-5/64

wire

INSULATOR,

nozzle

NOZZLE,

retaining

nut

SWITCH,

leaf

NUT,

hex

-jam

5/16-18

HANDLE,

gun

SCREW,

set

-

socket

hd

5

/16-18

SPRING,

0.21

ODx5/8

long

TRIGGER,

gun

TUBING,

glass

acrylic

No.

9

x

1/2

CORD,

power

(consisting

of)

HOUSING

PLUG

&

PINS

(consisting

of)

TERMINAL,

male

CLAMP,

cable

CORD,

No.

182/c

(orderbyft)

SPLICE,

parallel

20-16

wire

STRAIN

RELIEF

CONNECTOR,

cable

-

feeder

end

0-RING,

1/2

lDxO.103

GUIDE,

wire

-

outlet

.045

wire

GUIDE,

wire

-

outlet

1/16-5/64

wire

RING,

locking

SCREW,

set

hollow

lock

6-32

x

3/32

NUT,

connecting

-

cable

FITTING,

hose

-

gas

LINER,

monocoil

.045

wire

(consisting

of)

.O-RING,3/l6IDxO.103

COLLAR,

locking

SCREW,

set

hollow

lock

6-32

x

3/32

LINER,

monocoil

.0-RING,3/l6IDxO.103

COLLAR,

locking

SCREW,

set

hollow

lock

6/32

x

3/32

STRAIN

RELIEF,

extension

CABLE/CONDUIT,

10

ftor

CABLE/CONDUIT,

l5ft

RIVET,

solid

-

flared

hd

7/32

dia

x

1-1/4

long

SCREW,

set

-

socket

hd

10-32

x

1/4

CONNECTOR,

cable

-

gun

end

TUBING,

glass

-

acrylic

1/2

x

1-1/4

TUBE,

head6O

Optional

Equipment

047

959

045

638

046

776

046

775

OM-1

535

Page

2

Item

Part

No.

No.

Description

Quantity

Figure

A

Exploded

View

Of

GA-40C

Gun

(Contd.)

046

774

NOZZLE,

spot

-

outside

corner

1-1

/

16

ID

x

3-19/32

071

019

TUBE,

head

45

degree

072

819

TUBE,

head

45

degree

044 005

NOZZLE,

spot

-

fIat

1-1/2

ID

x

3.593

054

202

TUBE,

contact

.030-.035

wire

1-5/16

054

201

TUBE,

contact

.045

wire

1-5/16

047

576

TUBE,

contact

1/16

wire

x

1-7/16

047

577

TUBE,

contact

5/64

wire

1-7/16

044

006

TUBE,

contact

.052

wire

1-5/16

057

730

TUBE,

contact

.052

wire

1-7/16

046

001

TUBE,

head

80

046

002

TUBE,

head

straight

180

045

887

HEAT

SHIELD/HANGING

BRACKET

tFor

all

gun

lengths.

BE

SURE

TO

PROVIDE

MODEL

AND

STYLE

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1535

Page

3

/

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