September1988
FORM:
OM-1520A
Millerfi
MODEL
GA-50P
OWNERS
MANUAL
IMPORTANT
Read
and
understand
the
entire
contents
of
both
this
Miller
Electric
Mfg.Co.
manual
and
the
power
source
manual
used
with
this
unit,
with
special
Aue~G~ou~LldCor~ny
emphasis
on
the
safety
material
throughout
both
manuals,
before
in-
po.
Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
Appleton,
WI
54912
USA
Tel.
414-734-9821
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.
PRINTED
IN
U.S.A.
ADDITIONAL
COPY
PRICE
30
CENTS
N~7
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
16,
1988
if
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
defect
in
workmanship
andmaterial
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
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
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
honor
warranty
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.
Load
banks
1
year
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
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
orany
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repairor
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
author
ized
Miller
service
station
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
Use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Fac
tory
at
Appleton,
Wisconsin,
or
FOB,
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
ap
parent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
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
PERSONSTRAINED
AND
EXPE
RIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I.f
I
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusivewith
no
other
guarantees
or
warranties
expressed
or
implied.
I
ERRATA
SHEET
to
data
appearing
later
In
this
manual.
After
this
manual
was
printed,
refinements
In
equipment
design
occurred.
This
sheet
lists
exceptions
AMENDMENT
TO
SECTION
5
PARTS
LIST
Amend
Parts
List
as
follows:
All
Parts
Elf
w/KA-25
Quantity
Model
**First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
**
Part
No.
Replaced
With
10
FtAnd
15
Ft
1.6mm
2.0mm
.063
Description
1/16
in.
.079
5/64
in.
2-26
079
856
134
601
SLEEVE,
centering
monocoil
1 1
2-27
009
624
114
974
LINER,
monocoil
1/16-5.64
x
lift
6in
1 1
2-27
009
625
114
973
LINER,
monocoil
1/16-5/64
wire
x
l6ft
8in
....
1
1
2-28
079
852
134
600
GUIDE,
wire
outlet
1/1
6-5/64
1
1
SECTION
1
-
INTRODUCTION
Table
1-1.
Specifications
Ampere
Rating
100%
Duty
Cycle
(DCE~*)
Wire
Diamter
And
Type
Cable
And
Hose
Length
Cooling
Method
Net
Weight
Ship
Weight
500
Amoeres
With
~iO2
0045
through
1/8
in.
(1.1
throuoh
3.2
mm)
Hard
And
liux
Cored
10
ft.
(3.0
m)
Air
13
lbs.
(5.9
kg)
15
lbs.
(6.8
kg)
15
ft.
(4.5
m)
Air
15
lbs.
(6.8
kg)
17
lbs.
(7.6
kg)
*DC
Electrode
Positive
1-1.
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
output.
This
gun
is
rated
at
100%
duty
cycle.
This
means
that
the
gun
can
be
operated
continuously.
1-2.
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
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
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
applica
ble
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
Owners
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
WARNING
and
CAUTION
which
identify
differ
ent
levels
of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operation,
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,
IMPORTANT
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
ef
ficient
operation
of
this
equipment.
1-3.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam
age
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
WITH
THE
DELIVERING
CARRIER.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufacturers
Transportation
Department.
When
re
questing
information
about
this
equipment,
always
pro
vide
the
Model
Description
and
Serial
Number.
1-4.
DESCRIPTION
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal
Arc
Welding
(GMAW)
process.
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
the
wire
sizes
listed
in
Table
1-2.
Table
1-2.
WIre
Sizes
INCHES
MILLIMETERS
0.045
1.1
1/16
1.6
5/64
2.0
3/32
2.4
7/64
2.8
1/8
3.2
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
A
-
Air
Cooled
50
-
Ampere
Rating:
500
Amperes
P
-
Pistol
Grip
(Straight
Head
Tube)
OM-1520
Page
1
SECTION
2-INSTALLATION
4A
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
input
power
employing
locko
uttagging
procedures
before
inspecting
or
installing
gun.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
dis
connecting
device.
2-1.
GUN/FEEDER
ADAPTER
CONNECTION
(FIgure
2-1)
1.
Loosen
the
gun/feeder
connector
securing
knob
on
the
wire
drive
housing.
2.
Insert
the
gun/feeder
connector
into
the
drive
as
sembly
with
the
tip
of
the
connector
as
close
to
the
drive
rolls
as
possible
without
touching.
3.
Tighten
the
connector
securing
knob.
2-2.
GUN
SWITCH
CONNECTION
(Figure
2-1)
1.
Align
the
keyway,
and
insert
the
amphenol
gun
switch
connector
into
the switch
control
receptacle.
2.
Rotate
the
connector
collar
fully
clockwise
to
se
cure.
2-3.
SHIELDING
GAS
CONNECTION
(Figure
2-1)
1.
Connect
the
gas
hose
from
the
gun
to
the
gas
con
nector
on
the wire
feeder.
IMPORTANT:
The
shielding
gas
connector
has
right
hand
threading.
2.
Tighten
the
gas
connector.
Cable/Conduit
aFor
.045,
1/16,
or
5/64
in.
(1.1,
1.6,
or
2.0
mm)
Wire
Liners
Only
Figure
2-1.
Gun
Components
D-080
860-A
Nozzle
Head Tube
Body
Monocoil
Setscrew
Tube
Body
Centering
Sleeve*
Guide
Monocoll
Liner
Shieidlng
Gas
Connector
Switch
Connector
OM-1520
Page
2
SECTION
3-OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
FUMES
AND
GASES
can
derlously
harm
WELDING
WIRE
can
cause
puncture
your
health.
wounds.
Use
enough
ventilation
to
keep
fumes
and
Do
not
touch
five
electrical
parts.
gases
from
the
breathing
zone.
Do
not
point
gun
toward
any
part
or
the
body,
See
Section
1
Safety
Rules
For
Operation
other
personnel,
or
any
conductive
surface
Of
Arc
Welding
Power
Source
in
welding
when
threading
welding
wire.
power
source
Owners
Manual
for
basic
The
welding
wire
and
all
metal
parts
in
contact
welding
safety
information.
with
it
are
energized
when
gun
trigger
is
pressed.
3-1.
GUN
TRIGGER
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
Pressing
the
gun
trigger
energizes
the
welding
power
can
burn
eyes
and
skin;
NOISE
can
damage
source
contactor
and
initiates
wire
feeding.
Releasing
hearing,
the
trigger
deenergizes
the
contactor
and
stops
wire
Wear
correct
eye,
ear,
and
body
protection,
feeding.
SECTION
4
-
MAINTENANCE
4-1.
INSPECTION
AND
UPKEEP
4-2.
CONTACT
TUBE
REPLACEMENT
(FIgure
2-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
wounds;
HOT
SURFACES
can
cause
severe
burns,
burns.
Do
not
touch
live
electrical
parts.
0
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in-
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Allow
a
cooling
period
before
servicing.
Usage
and
shop
conditions
will
determine
frequency
1.
Remove
the
nozzle.
and
type
of
maintenance
required.
2.
Cut
oft
any
wire
that
extends
beyond
the
contact
1.
Inspect
gun
for
broken
areas,
cracks
and
loose
tube.
parts,
frayed
or
cracked
cable
insulation;
repair,
3.
Remove
the
contact
tube
and
replace
with
the
ap
tighten,
or
replace
as
required.
propriate
size
contact
tube.
2.
Remove
grease,
grime,
and
moisture
from
gun
han-
4.
Reinstall
the
nozzle
and
resume
operation.
die
and
cables.
4-3.
CLEANING
THE
MONOCOIL
LINER
AND
CAS
ING
(Figure
2-1)
a
CAUTION:
FLYING
DIRT
AND
METAL
PAR
TICLES
can
Injure
personnel
and
damage
WARNING:
ELECTRIC
SHOCK
can
kill;
equipment.
WELDING
WIRE
can
cause
puncture
Point
gun
liner
only
in
a
safe
direction
away
wounds;
HOT
SURFACES
can
cause
severe
from
personnel
and
equipment
when
cleaning
burns.
with
compressed
air.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
3.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air
whenever
changing
wire
or
liner.
Disconnect~gun
from
wire
feeder
before
in-
This
removes
any
loose
metal
chips
and
dirt
that
specting,
maintaining,
or
servicing.
may
have
accumulated.
Allow
a
cooling
period
before
servicing.
OM-1520
Page
3
Clean
the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
Fre
quency
of
cleaning
is
dependent
on
usage
and
operat
ing
conditions.
To
clean,
proceed
as
follows:
1.
Remove
the
nozzle.
2.
Cut
off
any
wire
that
extends
beyond
the
contact
tube.
CAUTION:
LOOSE
WELDING
WIRE
can
cause
Injury.
Keep
a
firm
hold
on
the
wire
during
installa
tion,
removal,
and
threading
operations.
Spooled
wire
has
a
tendency
to
unravel
rapidly
when
loosened
from
the
spool.
3.
Retract
the
remaining
welding
wire
onto
the
wire
spool
and
secure.
4.
Remove
the
contact
tube
(see
Figure
2-1).
5.
Disconnect
the
gun
assembly
from
the
control/
feeder.
6.
Remove
the
outlet
wire
guide
from
the
gun/feeder
connector.
7.
Loosen
the
monocoil
setscrews
on
the
gun
handle
and
the
insulator.
8.
Disconnect
the
gas
hose
from
the
gas
connector.
9.
Loosen
the
body
nut
and
remove
the
head
tube
body.
10.
Remove
the
head
tube.
11.
Pull
out
and
remove
the
monocoil
liner.
a
CAUTION:
FLYING
DIRT
AND
METAL
PAR
TICLES
can
injure
personnel
and
damage
equipment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
12.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air
to
remove
any
loose
metal
chips
and
dirt
that
may
have
accumuated.
13.
Lay
the
gun
and
cable
out
flat
and
straight
with
no
kinks
or
coils.
14.
Insert
monocoil
liner
fully
into
the
casing.
a
CAUTION:
OVERTIGHTENING
LINER
SETSCREWS
can
damage
monocoll
liner.
Do
not
overtighten
liner
setscrews.
15.
Tighten
the
liner
setscrews.
16.
Make
gun
connections
as
instructed
in
Section
2.
a
WARNING:
ELECTRIC
SHOCK
can
kIll;
WELDING
WIRE
can
cause
puncture
wounds;
ENERGIZED
WELDING
WIRE
may
cause
arcIng
when
touching
conductIve
ob
jects.
Do
not
touch
live
electrical
parts.
Do
not
point
gun
toward
any
part
of
the
body,
other
personnel,
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
in
pressed.
17.
Install
and
thread
the
welding
wire
(see
wire
feeder
Owners
Manual
for
procedure).
4-4.
CHANGING
LINER,
AND
WIRE
SIZES
(Figure
2-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
ilve
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.
Each
time
the
size
of
the
electrode
wire
is
changed,
it
is
necessary
to
change
some
of
the
gun
parts
such
as
the
contact
tube,
outlet
wire
guide,
and
liner.
These
changes
permit
smooth
wire
feeding.
See
the
wire
feeder
Owners
Manual
for
instructions
on
installing
the
inlet
wire
guide.
See
Table
4-1
for
the
required
parts
changeover
data.
a
OM-1520
Page
4
Table
4-1.
Wire
Size
And
Parts
Changeover
Data
From
This
Size
Wire
To
This
Size
0.45
in.
(1.143
mm)
1/16
in.
(1.589
mm)
5/64
in.
(1.984
mm)
3/32
in.
(2381
mm)
7/64
in.
(2.778
mm)
1/8
in.
(3.175
mm)
.045
in.
(1.143
mm)
N/A
1,2,3,
4,
7
1,2,3,
4,7
1,2,3,
4,
6,
7
1,2,3,
4,
6,
7
1,2,3,
4,
6,
7
1/161n.
(1.589
mm)
1,2,3,
4,7
N/A
1,2
1,2,3,
4,
6
1,2,3,
4,
6,
1,2,3,
4,
6
5/64
in.
(1.984
mm)
1,2,3,
4,
7
1,2
N/A
1,2,3,
4,
6
1,2,3,
4,
6
1,2,3,
4,
6
3/32in.
(2.381
mm)
1,2,3,
4,
5,
7
1,2,3,
4,
5
1,2,3,
4,
5
N/A
1,2
1,2
7/64in.
(2.778
mm)
1,2,3,
4,
5,
7
1,2,3,
4,
5
1,2,3,
4,
5
1,2
N/A
1,2
1/8in.
(3.165mm)
1,2,3,
4,5,7
1,2,3,
4,5
1,2,3,
4,5
1,2
1,2
N/A
Key:
I
=
Change
Contact
Tube
5
=
Insert
Rear
Centering
Sleeve
2
=
Change
Inlet
Wire
Guide
6
=
Remove
Rear
Centering
Sleeve
3
=
Change
Monocoil
Liner
7
=
Change
Head
Tube
4
Change
Outlet
Wire
Guide
To
perform
the
necessary
changes,
proceed
as
follows:
bly.
if
3/32
in.,
7/64
in.
or
1/8
in.
wire
is
to
be
used,
pro
ceedto
Step
11.
1.
Remove
the
nozzle
(see
Figure
2-1).
8.
Disconnect
gas
hose
from
gas
connector.
2.
Cut
off
any
wire
that
extends
beyond
the
contact
tube.
9.
Loosen
body
nut,
and
remove
head
tube
body.
10.
Remove
head
tube.
CAUTION:
LOOSE
WELDING
WIRE
can
______
cause
injury
11.
Pull
out
and
remove
monocoil
liner.
Keep
a
firm
hold
on
the
wire
during
installa-
CAUTION:
FLYING
DIRT
AND
METAL
PAR
tion,
removal,
and
threading
operations.
TICLES
can
Injure
personnel
and
damage
Spooled
wire
has
a
tendency
to
unravel
rapidly
equipment.
when
loosened
from
the
spool.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
3.
Retract
remaining
welding
wire
onto
wire
spool
and
secure.
12.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
4.
Remove
contact
tube.
compressed
air
whenever
changing
linerto
remove
any
loose
metal
chips
and
dirt
that
may
have
accu
5.
Disconnect
gun
assembly
from
control/feeder.
mulated.
6.
Remove
outlet
wire
guide
from
gun/feeder
connec-
IMPORTANT:
If
rear
centering
sleeve
does
not
require
tor.
changing,
proceed
to
Step
17.
IMPORTANT:
If
only
contact
tube
and
outlet
wire
guide
13.
Remove
insulator
from
gun/feeder
connector
to
need
to
be
changed,
proceed
to
Step
22.
gain
access
to
centering
sleeve
setscrew.
14.
Loosen
centering
sleeve
setscrew.
7.
Loosen
monocoil
setscrews
on
gun
handle
and
in-
15.
Add
or
remove
rear
centering
sleeve
as
determined
sulator.
by
wire
size
to
be
used.
When
adding
rear
centering
IMPORTANT:
Monocoll
liners
used
for
.045
in.
(1.143
sleeve,
proceed
as
follows:
mm),
1/16
in.
(1.589
mm),
or
5/64
in.
(1.984
mm)
wire
a.
Insert
centering
sleeve
into
gun/feederconnec
should
be
inserted
or
removed
from
gun
handle
end
of
tor.
gun
assembly
after
head
tube
body
and
head
tube
have
b.
Rotate
sleeve
until
notched
portion
lines
up
with
been
removed.
Liners
used
for
3/32
in,
(2.38
1
mm),
7/64
in.
(2.778
mm),
or
1/Sin.
(3.
175
mm)
wire
can
be
monocoil
setscrew
hole.
inserted
or
removed
from
insulator
end
of
gun
assem-
c.
Secure
centering
sleeve
setscrew.
OM-1520
Page
5
23.
Install
appropriate
outlet
wire
guide.
24.
Make
gun
connections
as
instructed
in
Section
2-1.
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
Do
not
touch
ilve
electrical
parts.
Do
not
point
gun
toward
any
part
of
the
body,
other
personnel,
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
in
pressed.
25.
Install
and
thread
the
welding
wire
(see
wire
feeder
Owners
Manual
for
procedure).
a
16.
Reposition
insulator
over
gun/feeder
connector.
17.
Lay
gun
and
cable
out
flat
and
straight
with
no
kinks
or
coils.
18.
Insert
new
monocoil
liner
fully
into
casing.
a
CAUTION:
OVERTIGHTENING
LINER
SETSCREWS
can
damage
monocoll
liner.
Do
not
overtighten
liner
setscrews.
19.
Tighten
liner
setscrews.
20.
Install
appropriate
size
head
tube
and
head
tube
body.
21.
Reconnect
gas
hose
to
gas
connector.
22.
Install
appropriate
size
contact
tube.
IMPORTANT:
The
new
monocoil
liner
will
be
longer
than
necessary.
Cut
off
excess
liner
flush
with
outlet
wire
guide.
Smooth
rough
edges.
OM-1520
Page
6
SECTION
5-
PARTS
11
Figure
A
Exploded
View
Of
Gun
Assembly
TD-080
861-A
10
9
7
8
7
6
30
4
3332
3
1
25
OM-1
520
Page
1
And
15FT
lOFT
1.2
mm
1.6
mm
.047
.063
.045
in.
1/16
in.
2.0mm
2.4
mm
2.8
mm
3.2
mm
.079 .094
.110
.126
5/64
in.
3/32
in.
7/64
in.
1/6in~
Figure
A
Exploded
View
Of
Gun
Assembly
1
073 476
1
073
476
2
078
289
3
078 852
4
007501
5
602179
6
075
671
7
073
779
8
007
395
8
007
394
9
007 550
10
054972
10
057
736
10
054545
10
054353
10
054354
10
054355
10
054356
11
008620
11
075
659
11
+075
662
11
+075
663
11
+075
665
11
+075
660
12
601
941
13
007579
14
049324
15
604311
16
004890
17
602240
18
079018
19
601
954
20
078 287
21
095949
22
076051
23
079021
24
601
865
25
605
789
26
079
856
27
009
627
27
009
628
27
009
624
27
009
625
27
007
594
27
007
595
28
079
852
28
079851
29
079 858
29
079
861
30
004731
31
048825
32
004
733
33
004
732
34
056462
CLAMP,
strap-rubber
5
holes
(10
ft.
models)
.. ..
10
CLAMP,
strap-rubber
5 holes
(15
ft.
models)
.. ..
15
HANDLE,
gun-left
hand
1
SCREW,
round
hd-1/4-28
x
1-1/4
2
WASHER,
flat-nylon
17/64
ID
x
7/160D
x
3/16
..
2
SCREW,
set-steel
socket
hd
1/4-20
x
1/2
1
NUT,
body
1
WASHER,
flat-phenolic
5/8
ID
x
1.11
OD
x
3/16..
2
TUBE,
head
0.045
wire
1
TUBE,
head
1/16-1/8
wire
BODY,
head
tube
1
TUBE,
contact
0.045
wire
or
1
TUBE,
contact
.052
wire
1
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
screw
type
1-3/16
x
2-3/8
1
NOZZLE,
screw
type
5/8
orifice
15/16
x
2-3/8..
1
NOZZLE,
spot-flat
2-5/8
long
1
NOZZLE,
spot-inside
2-5/8
long
1
NOZZLE,
spot-outside
3-1/8
long
1
NOZZLE,
15/16
orifice
x
2-3/8
SCREW,
cap-steel
hex
hd
1/4-20
x
1-3/4
1
BRACKET,
mounting
-
guard
handle
1
SCREW,
machine-brass
binding
hd
5-40
x
1/4
..
4
GROMMET,
rubber
1/4
ID
x
3/8
mounting
hole
..
1
GUARD,
trigger
1
WASHER,
flat-steel
1/4
1
NUT,
steel-hex
jam
1/4-28
2
SCREW,
cap-steel
hex
hd
1/4-20
x
3/4
1
HANDLE,
gun-right
hand
1
SPRING,
compression
1
INSULATOR,
adapter
1
SCREW,
set-steel
socket
hd
3/8-16
x
1/2
1
NUT,
steel-hex
full
1/4-20
1
SCREW,
set-steel
socket
hd
10-24
x
1/4
1
SLEEVE,
centering
-
monocoil
1
LINER,
monocoil
0.045
wire
x
10
ft
1
LINER,
monocoil
0.045
wire
x
15
ft
1
LINER,
monocoil
1/1
6-5/64
wire
x
10
ft
LINER,
monocoil
1/1
6-5/64
wire
x
15
ft
LINER,
monocoil
3/32-1/8
wire
10
ft
LINER,
monocoil
3/32-1/8
wire
l5ft
GUIDE,
wire-outlet
0.045-5/64
wire
1
GUIDE,
wire-outlet
3/32-1/8
wire
CABLE,
conduit
10
ft
(consisting
of)
1
CABLE,
conduit
15
ft.
(consisting
of)
1
ADAPTER,
head
tube/power
cable
1
ADAPTER,
gun/feeder
1
CLAMP,
cable-conduit
2
CLAMP,
cable-conduit
2
HOSE
ASSEMBLY,
gas
10
ft
(consisting
of)
1
10 10
10
10
10
15 15
15
15
15
1 1
1
1
1
2 2
2
2
2
2
2
2 2
2
1 1
1 1 1
1 1
1
1
1
2
2 2
2
2
1 1 1
1
1
1 1
1
1
1
1
1
1
1
1 1
1 1
1
1
1
1
1 1
1
1
1
1 1
1
1
1
1 1
1
1
1
1 1 1
1
1
1
1
1
2
2 2 2
2
2
2
2
2
2
1
1 1
1 1
Item
Factory
No.
Part
No.
Description
Quantity
Model
1
1
1
1
1 1
1 1
1
1
1 1
1
1
1
1
1 1
4
4
1
1
1
1
1 1
2
2
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1 1 1
1
1
1
1
1
1
1
1 1
4
4
4
1 1
1
1
1
1
1
1
1
2
2 2
1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
OM-1520
Page
2
10
FT
1.2mm
1.6mm
2.0mm
.047 .063
.079
O45in~
1/16in~
5/Bdit,
Figure
A
Exploded
View
Of
Gun
Assembly
(Contd)
HOSE
ASSEMBLY,
gas
15
ft
(consisting
of)
1
FITTING,
hose-brass
nut
5/8-18
RH
FITTING,
hose-brass
barbed
nipple
3/16
TBG
FITTING,
hose-brass
ferrule
.4215D
HOSE,
No.1
(order
by
ft)
CABLE,
trigger
10
ft
(consisting
of)
CABLE,
trigger
15
ft
(consisting
of)
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
CLAMP,
cable
CABLE,
No.
18
2/C
(order
by
ft
TERMINAL,
ring
tongue
No.
6
stud
SWITCH,
rocker
operated
DPST
8-16
amp
(consisting
of)
1
45
604 723
SCREW,
machine-brass
binding
hd
4-40
x
3/8
..
4
+079
196
FITTING,
hose-brass-barbed
F3/16TBGx1/4NPT
1
+056
851
FITTING,
hose-brass-barbed
nipple
3/16
TBG
...
1
aAS
Required
Optional
Equipment
i-These
items
used
when
attaching
a
50
series
feeder
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
The
Following
Parts
Are
Required
To
Change
The
Gun
Fire
from
One
Wire
Size
To
Another.
(Some
Parts
Are
Common
to
More
Than
One
Wire
Size.)
See
View
On
Page
1
For
Identification
Of
Item
Numbers.
Item
Factory
No.
Part
No.
8
007 395
8
007
394
10
054972
10
054545
10
054353
10
054354
10
054355
10
054356
25
605789
x
x
x
26
079856
..
x
x
x
27
009627
27
009
628
27
009624
X
X
27
009625
x
x
27
007594
x
x
x
27
007595
x
x
x
28
079
852
28
079851
X
X
X
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Factory
No.
Part
No.
Description
Quantity
Model
And
15FT
2.4mm
2.8
mm
3.2
mm
.094
.110
.126
~/~2in
7It~4in
1I~in
34
056 542
35
010606
36
056851
056
108
37 604 550
38
079
847
38
079
846
39
079
878
40
079
535
41
048834
42
604
525
43
079
040
44
011070
1
1 1
1
1
1 1
1
1
1
1
1 1 1
1
1
1
1 1
1
1
1
1
* * *
*
*
a
1
1 1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
1
1
1
a
* *
a
*
a
2
2
2
2
2
2
1
1
1
1
1
4 4
4
4
4
1 1
1
1
1
1
1
1
1
1
Quantity
Model
lOFT
1.2mm
I
1.6mm
.047
.063
Description
.045
~.
~
~
And
15FT
I2.Omm
I
.079
I
5/~4
~
l2.4mm
I
.094
I3Ki2
in
2.8mm
I
no
I7/~4
in
I3.2mm
I
.126
I
hR
in
x
x
TUBE,
head
0.045
wire
TUBE,
head
1/16-1/8
wire
TUBE,
contact
0.045
wire
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
SCREW,
set-steel
socket
hd
10-24
x
1/4
SLEEVE,
centering-monocoil
LINER,
monocoil
0.045
wire
x
10
ft
LINER,
monocoil
0.045
wire
x
15
ft
LINER,
monocoil
1/1
6-5/64
wire
x
lOft
LINER,
monocoll
1/1
6-5/64
wire
x
15
ft
LINER,
monocoil
3/32-1/8
wire
x
lOft
LINER,
monocoll
3/32-1/8
wire
x
15
ft
GUIDE,
wire-outlet
0.045-5/64
wire
GUIDE,
wire-outlet
3/32-1/8
wire
x
x
x
x
x
x
x
x
x
x
x
x
x x
x
OM-1520
Page
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