cover 7/93 – Ref. ST-161 935-A PRINTED IN USA
1993 MILLER Electric Mfg. Co.
Air-Cooled Gun For GMAW Welding
400 Amperes, 60% Duty Cycle Using CO
2
Shielding Gas
Feeds .035 To 5/64 in (0.9 To 2.0 mm) Hard Or Flux Cored Wires
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
September 1993 Form: OM-1535C
Effective With Style No. KA-09
GA-40C And GA-40CAL
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
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.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
sr7 7/93
SAFETY PRECAUTIONS FOR GMAW GUNS
WARNING
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. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
GMAW WELDING can be hazardous.
ARC RAYS can burn eyes and skin.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin with spatter-resistant
clothing.
ELECTRIC SHOCK can kill.
1. Always wear dry insulating gloves.
2. Insulate yourself from work and ground.
3. Do not touch live electrode or electrical parts.
4. Repair or replace worn, damaged, or cracked
gun or cable insulation.
5. Turn off welding power source before changing
contact tip or gun parts.
6. Keep all covers and handle securely in place.
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
HOT SURFACES can burn skin.
1. Allow gun to cool before touching.
2. Do not touch hot metal.
3. Protect hot metal from contact by others.
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING WIRE can cause puncture
wounds.
1. Keep hands and body away from gun tip when
trigger is pressed.
EMF INFORMATION
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
OM-1535 Page 1
SECTION 1 – SAFETY INFORMATION
mod1.1 8/92
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation – not related to safety.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
3
Turn OFF switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Welding Gun
Specifications Description
Rated Output 400 Amperes Using CO
2
Shielding Gas – Air-Cooled
Duty Cycle See Figure 2-1
Wire Diameter .035 To 5/64 in (0.9 to 2.0 mm)
Weight 10 ft Gun – Net: 8-1/4 lb (3.8 kg); Ship: 9-3/4 lb (4.4 kg)
15 ft Gun – Net: 11-3/4 lb (5.3 kg); Ship: 13-1/4 lb (6 kg)
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
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
sb1.5 8/93
0
10
Minutes
60% Duty Cycle At 400 Amperes Using CO
2
Definition
6 Minutes Welding 4 Minutes Resting
30% Duty Cycle At 400 Amperes Using Mixed Gases
3 Minutes Welding 7 Minutes Resting
Figure 2-1. Duty Cycle
OM-1535 Page 2
SECTION 3 – INSTALLATION
3-1. Preparing And Installing Gun
ST-152 466
1 Drive Assembly Cover
2 Drive Assembly
3 Gun Securing Knob
4 Gun End
Loosen securing knob. Insert gun
end through opening and position
as close as possible to drive rolls
without touching. Tighten knob.
5 Gun Trigger Plug
Insert into receptacle and tighten
threaded collar.
Close cover
See wire feeder manual for thread-
ing procedure.
1
4
5
3
2
Figure 3-1. Installing Gun
ST-156 235-A
3/32, 5/64, 1/4 in
Tools Needed:
Turn Off welding power source/wire feeder.
3/32 in
1/4 in
Remove set screws and pin Rotate head tube
Reassemble gun
180°
Be sure trigger leads
are not twisted.
Install setscrew
on this side.
Figure 3-2. Repositioning Head Tube
OM-1535 Page 3
SECTION 4 – OPERATION
READ SAFETY BLOCKS at beginning
of manual before proceeding.
WARNING
4-1. Operating The Gun
Ref. ST-150 093
1 Trigger Switch
When pressed, energized wire
feeds and shielding gas flows.
1
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.
3 Months
Control Cord
Gas Hose Gun Cable
– –
Replace
Cracked
Parts
Blow Out
Gun
Casing
Each Spool Of Wire
Clean
Nozzle
And Check
Contact Tip
– –
See
Figure
5-3
Figure 5-1. Routine Maintenance
Table 5-1. Troubleshooting
Trouble Remedy
Wire does not feed. Check contact tip. Check for kinks in gun cable. Check trigger connection at
welding power source/wire feeder. Have nearest Factory Authorized Service
Station/Service Distributor check gun trigger switch.
Wire is not energized. Check contact tip. Check trigger connection at welding power source/wire feed-
er. Have nearest Factory Authorized Service Station/Service Distributor check
gun trigger switch.
Wire feeds unevenly. Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.
5-2. Changing Contact Tip, Liner, And Head Tube
Ref. ST-156 234-A
Turn off welding power source/wire
feeder. Cut off wire at nozzle.
1 Nozzle
2 Contact Tip
3 Contact Tip Adapter
1
2
3
Tools Needed:
3/8 in
3/8 in
Figure 5-2. Changing Contact Tip
OM-1535 Page 4
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.
ST-156 234-B
To Reassemble Gun:
Insert new liner.
Hand tighten guide onto liner. Tight-
en 2 full turns more using wrench.
Cut liner off 1/4 in (6 mm) (3/8 in [9.5
mm] for aluminum) from head tube.
If liner is not close enough to drive
rolls, remove wire guide and adjust
collar. Do not overtighten setscrew.
Install adapter, contact tip and
nozzle.
Turn off welding power
source/wire feeder.
3/8 in
5/64 in
Head
3/8 in
Remove nozzle,
contact tip, adapter,
and wire outlet guide.
Loosen setscrew.
Blow out gun casing
Remove liner.
Tools Needed:
3/8 in
Tube
1/16, 5/64 in
Insert liner
Adjust collar so
liner is close to
drive rolls without
touching.
1/16 in
Figure 5-3. Changing Liner
OM-1535 Page 5
ST-800 346
Turn off welding power source/wire feeder.
Tools Needed:
3/8 in
5/64, 3/32, 1/4 in
3/8 in
3/32 in
1/4 in
Remove nozzle, contact tip, and adapter Separate handle
Install new head tube Reassemble handle
5/64 in
Reinstall sleeving on
terminals and insert
To adjust trigger,
turn setscrew in
until seated, then
out 1/2 turn.
paper between switch
and head tube.
Figure 5-4. Replacing Head Tube
OM-1535 Page 6
SECTION 6 – PARTS LIST
ST-049 927-J
10
9
8
6
5
7
4
3
Includes
Item 2
2
15
11
34
33
Includes
Items
39-41
38
37
36
35
29
28
34
33
32
41
40
29
31
39
30
19
2827
26
25
2314
22
21
18
16
17
13
11
12
19
20
Includes
Item 29
24
Includes
Items 14 & 15
1
Figure 6-1. Complete Assembly (GA-40C Gun Illustrated)
OM-1535 Page 7
Description
Part
No.
Item
No.
Figure 6-1. Complete Assembly
Quantity
GA-40C GA-40CAL
Model
1 046 115 TUBE, head 60deg (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 602 173 SCREW, set stl sch 10-32 x .250 cup point 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 070 592 TUBING, gl acryl .500-.524 ID (order by ft) 1ft 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 086 280 HOSE, nprn .500 ID x .687 OD x 4.500 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 081 960 RING, retaining ext .500 shaft x .035thk 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 047 603 NUT, conduit 1.125-18 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 094 986 INSULATOR, nozzle 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 094 985 ADAPTER, tube contact .035-.045 wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 094 987 ADAPTER, tube contact 1/16-5/64 wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 109 805 ADAPTER, tube contact .047al wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 054 183 TUBE, cont scr .035 wire x 1.437 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 054 157 TUBE, cont scr .045 wire x 1.437 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 047 566 TUBE, cont scr 1/16 wire x 1.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 047 565 TUBE, cont scr 5/64 wire x 1.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 057 730 TUBE, cont scr .052 wire x 1.437 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 047 957 NOZZLE, scr type .625 orf x 2.750 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 089 400 HANDLE, gun (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 112 244 NUT, handle/head tube 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 112 097 SCREW, set stl sch .500-13 x .375 cup point 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 049 312 RING, locking handle 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 112 096 PIN, spring CS .156 x 1.375 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 049 313 TRIGGER, gun (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 000 424 SCREW, set stl sch 8-32 x .250 oval point 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 059 294 SPRING, cprsn .210 OD x .026 wire x .625 lg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 081 959 SCREW, set stl hlk 6-32 x .093 plain 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 133 850 CONNECTOR, cable gun end 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 081 957 SWITCH, leaf type 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 070 585 TUBING, gl acryl .162-.178 ID (order by ft) 1ft 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 081 909 SPLICE, prl 16-14 wire nyl insul 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 049 872 CABLE, power (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 604 525 CABLE, port No. 18 2/c (order by ft) 2ft 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 048 834 CLAMP, cable strain relief sz 11 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 079 878 HOUSING PLUG & PINS, (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 535 TERMINAL, male 1 pin 18-14 wire 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 091 602 STRAIN RELIEF, cable (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 049 312 RING, locking handle 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 079 974 O-RING, .500 ID x .103CS rbr 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 047 555 GUIDE, wire outlet .045 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 047 556 GUIDE, wire outlet 1/16-5/64 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 109 797 GUIDE, wire outlet .047al 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 133 852 CONNECTOR, cable feeder end 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 049 876 NUT, connecting cable 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 133 851 FITTING, hose gas 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 112 884 STRAIN RELIEF, extension feeder end 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 047 572 CABLE/CONDUIT, 10ft or 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 047 573 CABLE/CONDUIT, 15ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 049 298 STRAIN RELIEF, extension cable gun end 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 ♦083 891 LINER, monocoil .045 wire (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 081 959 SCREW, set stl hlk 6-32 x .093 plain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 049 307 COLLAR, locking liner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 ♦083 897 LINER, monocoil 1/16-5/64 wire (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 081 959 SCREW, set stl hlk 6-32 x .093 plain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 047 557 COLLAR, locking liner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1535 Page 8
Description
Part
No.
Item
No.
Figure 6-1. Complete Assembly (Continued)
Quantity
GA-40C GA-40CAL
Model
38 109 807 LINER, monocoil .047al wire (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 081 959 SCREW, set stl hlk 6-32 x .093 plain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 109 799 COLLAR, locking liner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 853 CLAMP, cable/conduit 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦ For All Gun Lengths
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Optional Equipment
Description
Quantity
Part
No.
Item
No.
GA-40C GA-40CAL
Model
1 046 116 HEAD TUBE, straight (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 071 019 TUBE, head 45deg (consisting of) X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 602 173 SCREW, set stl sch 10-32 x .250 cup point X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 049 854 TUBING, gl acryl .500-.524 ID x 2.562 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 086 280 HOSE, nprn .500 ID x .687 OD x 4.500 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 081 960 RING, retaining ext .500 shaft x .035thk X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
046 071 HEAD TUBE, 80deg .035-.045 wire (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
046 073 HEAD TUBE, 80deg 1/16-5/64 wire (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 046 113 TUBE, head 80deg (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 602 173 SCREW, set stl sch 10-32 x .250 cup point X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 049 854 TUBING, gl acryl .500-.524 ID x 2.562 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 086 279 HOSE, nprn .500 ID x .687 OD x 5.750 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 081 960 RING, retaining ext .500 shaft x .035thk X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 083 891 LINER, monocoil .030-.045 wire x 15ft (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . .
38 083 897 LINER, monocoil 1/16-5/64 wire x 15ft (consisting of) X. . . . . . . . . . . . . . . . . . . . . . . . . . .
39 081 959 SCREW, set stl hlk 6-32 x .093 plain X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 049 307 COLLAR, locking liner (.030-.045 wire) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 047 557 COLLAR, locking liner (1/16-5/64 wire) X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 079 975 O-RING, .187 ID x .103CS rbr X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 054 202 TUBE, cont scr .030-.035 wire x 1.312 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 054 201 TUBE, cont scr .045 wire x 1.312 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 071 212 TUBE, cont scr tapered .035 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 071 213 TUBE, cont scr tapered .045 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 071 211 TUBE, cont scr .052 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 044 006 TUBE, cont scr .052 wire x 1.312 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 057 730 TUBE, cont scr .052 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 047 576 TUBE, cont scr 1/16 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 047 577 TUBE, cont scr 5/64 wire x 1.437 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 044 005 NOZZLE, spot flat 1.500 ID x 3.093 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 046 776 NOZZLE, spot flat 1.062 ID x 3.593 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 046 775 NOZZLE, spot inside corner 1.062 ID x 3.593 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 046 774 NOZZLE, spot outside corner 1.062 ID x 3.468 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 045 638 NOZZLE, scr type .812 orf x 2.750 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 047 959 NOZZLE, scr type .500 orf x 2.750 X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 071 214 NOZZLE, scr type tapered .375 orf x 2.750 X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
045 887 HEAT SHIELD X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
9/92
OPTIONS AND ACCESSORIES
DSS–8 DUAL SCHEDULE
SWITCH
(#079 691) 10 ft. (3 m)
(#079 693) 15 ft. (4.6 m)
Fastens to gun handle. Used in
place of standard gun trigger.
Selects schedule and operates the
contactor.
Note: Adapter cord (#046 943) is required
when using a DSS–8 switch with an
RCMP–1 or RCDW–1 control and S–52A
or S–54A wire feeder.
DSS–9 DUAL SCHEDULE
SWITCH
(#071 832) 10 ft. (3 m)
(#071 833) 15 ft. (4.6 m)
Fastens to gun handle. Selects
schedule. Gun trigger switch
operates the contactor.
Note: Adapter cord (#046 943) is required
when using a DSS–9 switch with an
RCMP–1 or RCDW control and S–52A or
S–54A wire feeder.
DSS–10 DUAL SCHEDULE
SWITCH
(#042 749)
Fastens to gun handle. To be used
on a variety of semiautomatic
air–cooled torches used with
Millermatic 250MP power source.
Switch increases or decreases
selected wire feed values.
TRIGGER SWITCH
(#079 885) 10 ft. (3 m)
(#079 854) 15 ft. (4.6 m)
Includes cord and plug. Required
when used with Swingarc,
Porta–Mig, or the 50 Series
feeders.
ADAPTERS for GA–20C,
GA–21C, and GA–21CM
(#048 622)
Connects gun to MM–10 and
MM–30 Series wire feeders.
(#071 243)
Connects gun to MM–70A wire
feeder.
ADAPTERS for GA–40C
(#047 540)
Connects gun to MM–10 and
MM–30 Series wire feeders. .035
in. and .045 in. (0.9 and 1.1 mm)
wire
(#047 541)
Connects gun to MM–10 and
MM–30 Series wire feeders. 1/16
in. and 5/64 in. (1.6 and 2.0 mm)
wire
(#071 243)
Connects gun to MM–70A wire
feeder. .035 in. and .045 in (0.9
and 1.1 mm) wire
HEAT SHIELD
(#045 887 Field)
Shields operator’s hands from
excessive heat.
CONVERSION KIT
(#109 508)
Allows 10 ft. (3 m) GA–40C gun to
feed 3/64 in. (1.2 mm) aluminum
wire. Includes one liner, four
contact tips, one outlet guide and
one contact tip adapter.
Important: Nylon Inlet (#058 854) and
Intermediate Guides (4 roller feeders)
(#058 853) are recommended for Miller
feeders when using aluminum wire.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
miller_warr 7/00
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.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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.
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1. 5 Years Parts – 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 & Spoolmate 250
* Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies 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 repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Always provide Model Name and Serial/Style Number.
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
For Service
Owner’s Record
File a claim for loss or damage during
shipment.
Contact your Distributor for:
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Miller KA09 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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