Miller GA-40GL Owner's manual

Miller
Brand
Miller
Model
GA-40GL
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
July
1991
FORM:
OM-1515C
Effective
With
Serial
No.
Style
No.
JD-29
MODEL:
GA-4OGL
T~1~
~7~3
c~~
J~7~
OWNERS
MANUAL
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
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
Instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.,
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
ST.091
915-A
PRINTED
IN
LISA.
.
I
I
L
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nished
by
Miller
is
free
from
defectin
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year.
such
as
spot
welder
tips,
relay
and
contactor
points.
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Loadbanks
Iyear
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
Miller
may
honor
daims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repairorreplacementwill
be
F.O.B.,
Factory
atAppleton,
Wisconsin,
or
F.O.B.
ata
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPUED
WARRANTY~
GUARANTY
OR
REPRE
SENTATiON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FORTHIS
PRO
ViSION,
MIGHT
ARiSE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPUED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITiNG,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUThORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~~1
/
.1
I
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
trou
bleshooting
which
should
be
read,
understood,
and
fol
lowed
for
the
safe
and
effective
use
of this
equipment.
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
the
front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source
in
the
welding
power
source
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2INTRODUCTION
Table
2-1.
Specifications
2-1.
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
out
put
without
overheating
and
damaging
the
gun.
This
gun
is
rated
at
60%
duty
cycle.
This
means
the
gun
can
be
operated
at
400
amperes
for six
minutes
out
often.
Dur
ing
the
remaining
four
minutes,
the
gun
must
operate
at
no
load
to
permit
proper
cooling.
If
rated
amperage
is
ex
ceeded,
the
duty
cycle
must
be
reduced.
2-2.
DESCRIPTION
This
gun
is
designed
specifically
for
use
with
the
self-
shielding
Flux
Cored
Arc
Welding
(FCAW)
process
us
ing
self-shielding
flux
cored
electrode.
The
gun
may
be
used
for
either
electrode
positive/dc
reverse
or
electrode
negative/dc
straight
polarity
applications.
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
.045,
1/16,
.068/.072,
5/64,
or
3/32
in.
(1.2,
1.6,
1.8,
2.0,
or
2.4
mm)
flux
cored
wire.
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
A
Air
Cooled
40
Ampere
Rating:
400
Amperes
GL
Gasless
Ampere
Rating
60%
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
Ship
400
Amperes
.045
(1.2
mm)
1/16
in.
(1.6
mm)
.068/.072
in.
(1.7/1.8
mm)
5/64
in.
(2.0
mm)
3/32
in.
(2.4
mm)
lOft.
(3.0
m)
15ft
(4.6
m)
Air
8.5
lbs.
(3.9
kg)
10.5
lbs.
(4.8
kg)
10.5
lbs.
(4.8
kg)
12.5
lbs.
(5.7
kg)
a
CAUTION:
EXCEEDING
THE
RATED
AM
PERAGE
OR
DUTY
CYCLE
can
result
in
dam
age
to
the
gun.
Do
not
exceed
rated
amperage
or
duty
cycle.
OM-1515
Page
1
a
1-3/4
in.
(44.5
mm)
Nozzle
Figure
3-1.
Gun
Components
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employ
ing
lockout/tagging
procedures
before
in
specting
or
installing
gun.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
discon
necting
device.
3-1.
GUN/WIRE
(Figure
3-1)
FEEDER
CONNECTIONS
Install
the
gun/feeder
adapter
into
the
drive
assembly
on
the
wire
feeder
as
follows:
IMPORTANT:
The
wire
outlet
guide
is
provided
as
part
of
the
gun
assembly.
1.
Loosen
the
gun/feeder
connector
securing
knob
on
the
wire
drive
assembly.
Monocoii
Liner
Setscrew
Strain
Relief
Gun/Feeder
Adapter
Half
~
~
Handle
Locking
Ring
~~Strain
Relief
Half
IMPORTANT:
Wire
guides
should
be
installed
so
that
the
tip(s)
of
the
guide
is
as
close
to
the
drive
roll
as
possi
ble
without
touching.
2.
Insert
gun
into
wire
drive
assembly
until
gun/feed
er
connector
stops
against
wire
drive
assembly.
3.
Tighten
gun/feeder
connector
securing
knob.
3-2.
GUN
SWITCH
CONNECTIONS
(Figure
3-1)
Connect
gun
trigger
switch
connector
into
TRIGGER
re
ceptacle
on
wire
feeder
as
follows:
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
Depressing
the
gun
trigger
energizes
the
welding
power
source
contactor
and
initiates
wire
feeding.
Releasing
the
trigger
drops
out
the
contactor
and
stops
wire
feed
ing.
3-3.
NOZZLE
(Optional)
(Figure
3-1)
These
items
can
be
used
in
place
of
the
standard
thread
protector.
See
parts
list
for
identification
and
informa
tion.
SECTION
3
INSTALLATION
Thread
Protector
Contact
Tube
Wire
2-3/8
in.
(60.3
mm)
Nozzle
Monocoil
Liner
Cable
Extension
Strain
Relief
Handle
Locking
Ring
Gun
Switch
~ctor
SC-091
914-C
OM-1
515
Page
2
SECTION
4
SEQUENCE
OF
OPERATION
4-1.
FLUX
CORED
ARC
WELDING
1.
Be
sure
that
proper
electrical
connections
have
a
WARNING:
ELECTRIC
SHOCK
can
kill;
been
made
to
the
welding
power
source
and
the
MOVING
PARTS
can
cause
serious
injury;
wire
feeder.
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.
2.
Select
and
obtain
proper
welding
wire,
and
thread
as
instructed
in
wire
feeder
Owners
Manual.
Do
not
touch
live
electrical
parts.
Do
not
touch
welding
wire
or
any
metal
part
in
~
Wear
dry
insulated
gloves
and
clothing.
contact
with
the
wire
while
welding.
4.
Connect
work
clamp
to
clean,
bare
metal
at
work-
The
welding
wire
and
all
metal
parts
in
contact
piece.
with
it
carry
weld
output
when
the
gun
switch
is
depressed.
5.
Place
the
wire
feed
control(s)
in
the
required
posi
Keep
all
covers
and
panels
in
place
while
op-
tion
for
the
welding
setup.
erating.
6.
Place
the
controls
on
the
welding
power
source
in
Warranty
is
void
if
the
welding
power
source
is
the
required
position
for
the
welding
setup
(refer
operated
with
any
portion
of
the
outer
enclosure
to
welding
power
source
Owners
Manual).
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
7.
Wear
welding
helmet
with
proper
filter
lens
ac
can
burn
eyes
and
skin;
NOISE
can
damage
cording
to
ANSI
Z49.1.
hearing.
8.
Energize
the
welding
power
source
and
the
wire
Wear
correct
eye,
ear,
and
body
protection.
feeder
(refer
to
the
respective
Owners
Manual).
FUMES
AND
GASES
can
seriously
harm
your
health.
9.
Close
drive
roll
housing,
and
adjust
tension
(see
Keep
your
head
out
of
the
fumes.
appropriate
Owners
Manual).
Ventilate
to
keep
from
breathing
fumes
and
10.
Pressthe
gun
trigger,
and
run
the
welding
wire
out
gases.
beyond
the
end
of
the
nozzle.
Cut
the
wire
off
so
it
If
ventilation
is
inadequate,
use
approved
extends
out
1/4
to
3/8
in.
(6.4
mm
to
9.5
mm)
from
breathing
device,
end
of
nozzle.
WELDING
WIRE
can cause
puncture
11.
Set
the
Wire
Speed
control
slightly
higher
than
wounds.
anticipated
wire
speed.
Do
not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
12.
Hold
the
end
of
the
nozzle
approximately
1/2
in.
(12.7
mm)
from
the
workpiece.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
13.
Press
the
gun
trigger.
Wire
starts
to
feed,
and
the
Watch
for
fire.
arc
will
be
established.
If
the
welding
wire
ap
pears
to
slip,
adjust
drive
roll
tension
according
to
Keep
a
fire
extinguisher
nearby,
and
know
wire
feeder
Owners
Manual.
how
to
use
it.
Do
not
use
near
flammable
material.
14.
After
the
controls
on
the
welding
power
source
and
the
wire
feeder
(if
applicable)
have
been
ad-
Allow
work
and
equipment
to
cool
before
han-
justed
for
normal
operation,
the
welding
power
source
(and
wire
feeder)
will
function
automati
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
cally
when
the
gun
trigger
is
pressed.
Releasing
can
aftect
pacemaker
operation.
the
gun
trigger
will
extinguish
the
arc
and
cause
Wearers
should
consult
their
doctor
before
the
wire
feed
to
stop.
going
near
arc
welding,
gouging,
or
spot
weld
ing
operations.
4-2.
SHUTTING
DOWN
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
welding
power
1.
Stop
welding.
source
Owners
Manual
for
basic
welding
safety
information.
2.
Turn
off
welding
power
source
and
wire
feeder.
OM-1515
Page
3
SECTION
5
MAINTENANCE
a
CAUTION:
INCORRECT
HEAD
TUBE
AS
SEMBLY
can
cause
contact
tube
threads
to
strip.
Wire
insert
and
hollow
setscrew
must
be
in
head
tube
before
installing
contact
tube.
When
the
wire
insert
and
hollow
setscrew
are
not
properly
installed,
the
contact
tube
can
be
threaded
too
far
into
the
head
tube
causing
the
threads
on
the
contact
tube
to
strip.
See
Figure
3-1
for
correct
assembly.
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance.
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts:
tighten,
repair
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
dirt
that
has
accumulated
around
nozzle
opening
and
inside
nozzle.
3.
Repair
or
replace
as
required
all
hose
and
cables;
give
particular
attention
to
frayed
and
cracked
in
sulation
and
areas
where
it
enters
equipment.
4.
Remove
grease
and
grime
from
components
and
moisture
from
electrical
parts
and
cables.
5.
Blow
out
casing
with
compressed
air
when
changing
wire.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
See
Section
5-3
for
complete
procedure.
a
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
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.
(Figure
3-1)
TUBE
A~
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Remove
nozzle.
2.
Cut
off
any
portion
of
electrode
wire
which
ex
tends
beyond
end
of
contact
tube.
3.
Remove
contact
tube,
and
replace
with
new
con
tact
tube.
4.
Reinstall
nozzle,
and
resume
operation.
5-3.
CLEANING
MONOCOIL
LINER
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Periodically,
depending
on
usage
and
conditions,
it
will
be
necessary
to
clean
the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt
that
may
have
accumu
lated.
To
clean,
proceed
as
follows:
1.
Retract
wire
onto
wire
spool.
2.
Disconnect
gun
from
wire
feeder.
3.
Remove
setscrew
from
gun/feeder
connector
and
from
head
tube
(via
clearance
hole
on
top
of
handle).
4.
Lay
cable
out
straight,
and
pull
monocoil
liner
out
from
gun/feeder
connector
end.
a
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
can
injure
personnel
and
damage
equip
ment.
Point
gun
ilner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
5.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air.
5-2.
CONTACT
REPLACEMENT
OM-1515
Page
4
6.
Lay
cable
out
straight.
7.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly
against
wire
insert
(see
Figure
3-1).
a
CAUTION:
OVERTIGHTENING
LINER
SET
SCREWS
will
damage
monocoil
liner.
Do
not
overtighten
liner
setscrews.
8.
Tighten
setscrews
in
head
tube
and
gun/feeder
connector.
9.
Reinstall
gun
and
rethread
welding
wire.
10.
Resume
operation.
5-4.
CHANGING
WIRE
SIZES
(Figure
3-1)
f~,
WARNING:
ELECTRIC
SHOCK
can
kill;
~
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
When
changing
the
gun
from
.045
in.
(1.1
mm)
wire
to
any
other
wire
size
or
vice
versa,
it
is
necessary
to
change
the
contact
tube,
gun/feeder
connector,
liner,
and
wire
guides
(for
inlet
guide
installation,
refer
to
the
appropriate
welding
power
source
or
wire
feeder
Own
ers
Manual).
1.
Remove
nozzle,
if
applicable.
2.
Cut
off
any
portion
of
the
electrode
wire
which
ex
tends
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.
Loosen
the
monocoil
liner
setscrew
in
head
tube
(located
in
clearance
hole
on
top
of
handle)
and
in
gun/feeder
connector.
7.
Lay
the
gun
and
cable
assembly
out
flat
and
straight
(no
coils
in
the
cable/conduit).
8.
Pull
out
liner
from
gun/feeder
connector
end
of
gun
assembly.
a
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
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.
9.
Blow
out
gun
casing
or
liner
with
compressed
air
whenever
the wire
or
liner
is
removed.
10.
Rotate
handle
locking
rings
to
release
and
re
move
rings
from
strain
relief.
11.
Separate
and
remove
strain
relief
halves
from
cable
extension
strain
relief.
12.
Remove
and
replace
existing
gun/feeder
connec
tor
with
a
connector
for
new
wire
size.
13.
Reinstall
strain
relief
halves
onto
cable
extension
strain
relief.
14.
Reinstall
and
rotate
locking
rings
securing
them
over
the
strain
relief.
a
CAUTION:
OVERTIGHTENING
LINER
SET
SCREWS
will
damage
monocoil
liner.
Do
not
overtighten
liner
setscrews.
15.
Insert
new
liner
into
gun/feeder
connector
end
of
gun
assembly
until
it
seats
firmly
against
wire
in
sert.
16.
Tighten
setscrews
in
head
tube
and
gun/feeder
connector.
17.
Install
new
contact
tube.
18.
Reinstall
nozzle,
if
applicable.
IMPORTANT:
If
new
monocoll
liner
extends
beyond
the
end
of
the
gun/feeder
connector,
cut
liner
off
even
with
end
of
connector.
19.
Make
gun
connections
as
instructed
in
Section
3-1
and
3-2.
20.
Install
and
thread
new
size
electrode
wire
(see
wire
feeder
Owners
Manual
for
procedure).
21.
Resume
operation.
OM-1515
Page
5
SECTION
6
PARTS
LIST
11
Figure
6-1.
Main
Assembly
24~
SC-091
9t4-C
1
2
10
12
3
9
8
7
4
6
13
14
33
15
16
2
17
18
30
23
22
32
21
31
29
Includes
.
27
26~
25
OM-1515
Page
6
Figure
6-1.
Main
Assembly
Description
Quantity
11
....
052078
12
052059
13
....
052
075
14
091850
15
052095
16
601856
17
602207
18
601865
19
091705
19
091704
20
049312
21
112884
22
091860
23
602173
24
094816
24
091843
25
091838
25
091836
26
079878
079
535
27
048834
28
604525
29
053132
30
000369
31
083946
31
081580
31
083945
31
081581
32
052071
33
052919
OPTIONAL
WIRE
GUIDE,
insulated
1
.750
Ig
(all
available
wire
sizes)
PROTECTOR,
thread
WIRE
GUIDE,
insulated
2.375
Ig
(all
available
wire
sizes)
SHIELD,
hand
1
SCREW,
set
sti
sch
.312-18
x
.500
cone
point
NUT,
weld
.312-18
WASHER,
lock
stl
split
.250
NUT,
sti
hex
full
.250-20
CABLE/CONDUIT,
lOft
CABLE
CONDUIT,
lSft
RING,
locking
handle
STRAIN
RELIEF,
extension
gun
end
STRAIN
RELIEF
SCREW,
set
sti
sch
10-32
x
.250
cup
point...
ADAPTER,
gun/feeder
ADAPTER,
gun/feeder
CABLE,
switch
lift
(consisting
of)
CABLE,
switch
16ft
(consisting
of)
HOUSING
PLUG
&
PINS,
(consisting
of)
TERMINAL,
male
1
pin
18-14
wire
CLAMP,
cable
strain
relief
sz
11
CABLE,
port
No.
18
2/c
(order
by
ft)
STRAIN
RELIEF,
cable
SWITCH,
lim
1OA
125/25OVAC
DPST
LINER,
monocoi~
.030-.045
wire
x
lift
6in
LINER,
monocoil
stl
.230
OD
x
.030-.125
wire
x
llft
6in
LINER,
monocoil
.030-.045
wire
x
1
6ft
6in
LINER,
monocoil
stl
.230
OD
x
.030-.125
wire
x
16ft
6in
CLAMP,
tube
head
SCREW,
mach
stl
rdh
.250-20
x
.875
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
No.
Part
No.
.
.
1
..
601
957
SCREW,
cap
sti
hexhd
.250-20
x
1.500
..
.
2
..
091
859
HANDLE,
gun
.
.3
..
076762
PIN,springCS.093x.750
.
.
4
..
057
544
SPRING,
cprsn
.240
OD
x
.026
wire
x
1.000
..
..
.
.
5
..
052 064
TRIGGER,
gun
.
..
.
6
..
091
706
SCREW,
set
stl
sch
.250-28
x
.312
cup
point
.
.
..
:
7
..
091
841
TUBE,
hd
.
.
8
..
052 074
INSERT,
wire
.
.
9
..
052
098
SCREW,
set
sti
hlk
.375-16
x
.187
...
10
..
045 356
TUBE,
cont
scr
.045
wire
x
1.125
..
10
..
090
922
TUBE,
cont
scr
.072
wire
x
1.125
..
10
..
009 709
TUBE,
cont
scr
1/16
wire
x
1
.125
..
10
..
052 055
TUBE,
cont
scr
5/64
wire
x
1.125
..
10
..
008 926
TUBE,
cont
scr
3/32
wire
x
1.125
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I
1
2
1
2
1
1
1
1
1
1
1
1
4
1
As
Reqd
1
1
.1
OM-1515
Page
7
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10

Miller GA-40GL Owner's manual

Miller
Brand
Miller
Model
GA-40GL
Category
Welding System
Type
Owner's manual
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