GA-50C

Miller GA-50C, JA000000 Owner's manual

Hello! I am an AI chatbot trained to assist you with the Miller GA-50C Owner's manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
What is the maximum amperage output of the Miller GA-50C welding gun?

What type of wire can be used with the Miller GA-50C welding gun?

What type of shielding gas is required for the Miller GA-50C welding gun?

What is the recommended duty cycle for the Miller GA-50C welding gun?

What is the net weight of the Miller GA-50C welding gun?

December

1980

FORM:

OM-1519

FALE

COPY

RETURN

TO

FOLDER

OWNERS

MANUAL

HilliER

:11

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

20

CENTS

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

MODEL

GA-50C

L~

L~P

9~.~

~

t~.~$~

LIMITED

WARRANTY

EFFECTIVE:

JUNE

1,

1979

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

conditions

As

a

matter

of

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.

Appleton,

Wisconsin

warrants

submitted

by

the

original

user

within

the

foregoing

periods.

to

its

Distributor/Dealer

that

all

new

and

unused

Equipment

(

furnished

by

Miller

is

free

from

defect

in

workmanship

and

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

material

as

of

the

time

and

place

of

delivery

by

Miller.

No

war-

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

ranty

is

made

by

Miller

with

respect

to

engines,

trade

ac-

therefore

shall

be,

at

Millers

option

Ill

repair

or

(2)

replacement

cessories

or

other

items

manufactured

by

others.

Such

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(31

(

engines,

trade

accessories

and

other

items

are

sold

subject

to

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

the

warranties

of

their

respective

manufacturers,

if

any

.

All

Miller

service

station

or

141

payment

of

or

credit

for

the

purchase

engines

are

warranted

by

their

manufacturer

for

one

year

from

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

date

of

original

purchase.

return

of

the

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

cia)-

~

Except

as

specified

below,

Millers

warranty

does

not

apply

mant

on

the

warranty

claim

procedures

to

be

followed.

to

components

having

normal

useful

life

of

less

than

one

11)

year,

such

as

spot

welder

tips,

relay

and

contactor

points,

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

MILLERMATIC

parts

that

come

in

contact

with

the

welding

ANY

IMPLIED

WARRANTY,

GUARANTY

OR

REPRESENTA-

?

wire

including

nozzles

and

nozzle

insulators

where

failure

does

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

not

result

from

defect

in

workmanship

or

material.

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

k~

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

Miller

shall

be

required

to

honor

warranty

claims

on

war-

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

INCLUDING

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

OF

within

the

following

periods

from

the

date

of

delivery

of

Equip-

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

(

ment

to

the

original

user:

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EX

CLUDED

AND

DISCLAIMED

BY

MILLER.

1.

Arc

welders,

power

sources

and

components

. .

1

year

2.

Original

main

power

rectifiers

3

years

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

(labor

-

1

year

only)

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

3.

All

welding

guns

and

feeder/guns

90

days

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

4.

All

other

Millermatic

Feeders

1

year

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED,

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor

.

60

days

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

6.

Batteries

6

months

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

~4

CONSUMER

USE.

MILLER

WARRANTIES

DO

NOT

EXTEND

~

provided

that

Miller

is

notified

in

writing

within

thirty

(30)

days

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO EXTEND

of

the

date

of

such

failure.

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

~,

a

a

~t,

a

~%

j~..

.~t

%

a

a a 4

SECTION

1

-

INTRODUCTION

Rating:

100

PCT.

Duty

Cycle,

dcrp

Wire

Dia.

Cable

And

Hose

Length

Cooling

Method

Net

Weight

Ship

Weight

500

Amperes

.045

(1.1

mm)

To

10

Air

12

lb.

(5.4

kg)

14

lb.

(6.4

kg)

With

C02

1/8

(3.1

mm)

Flux

Cored

15

Air

14

lb.

(6.4

kg)

16

lb.

(7.3

kg)

Figure

1-1.

Specifications

1-1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

Information

presented

in

this

manual

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.

B.

Safety

The

installation,

operation,

maintenance,

and

troubleshooting

of

arc

welding

equipment

requires

practices

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

in

the

welding

power

source

or

welding

generator

Owners

Manual

at

the

end

of

Section

1

-

Safety

Rules

For

Operation

Of

Arc

Welding

Power

Source.

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

serious

personal

injury

or

loss

of

life.

IMPORTANT,

Another

signal

word,

highlights

in

structions

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

and

freight

bill

will

be

furnished

by

the

carrier

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

it

is

essential

that

Model

Description

of

the

equip

ment

be

supplied.

Safety

instructions

specifically

pertaining

to

this

unit

ap

pear

throughout

this

manual

highlighted

by

the

signal

words

WARNING.

1-3.

DESCRIPTION

-

This

gun

is

designed

specifical

ly

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

.045,

1/16,

5/64,

3/32, 7/64,

or

1/8

wire.

SECTION

2

-

INSTALLATION

WARNING

ELECTRIC

SHOCK

can

kill.

Shut

down

the

wire

feeder

and

welding

power

source

and

be

sure

they

cannot

be

accidentally

energized

while

installing

the

gun.

2-1.

SHIELDING

GAS

CONNECTION

(Figure

2-1)

-

Connect

the

gas

hose

from

the

gun

to

the

gas

connector

from

the

wire

feeder.

The

shielding

gas

con-



nector

has

right-hand

threading.

2-2.

GUN

SWITCH

CONNECTIONS

-

Align

the

keyway

and

insert

the

amphenol

gun

switch

(trigger)

connector

into

the

switch

control

(trigger)

receptacle.

Rotate

the

connector

collar

clockwise

to

lock

the

con

nector

in

the

receptacle.

2-3.

GUN/FEEDER

CONNECTOR

CONNEC

TION

-

Install

the

gun/feeder

connector

into

the

drive

assembly

as

follows:

1.

Loosen

the

gun/feeder

connector

securing

knob.

2.

Insert

the

gun/feeder

connector

into

the

hole

provided

in

the

drive

assembly

opposite

the

inlet

wire

guide.

3.

Tighten

the

gun/feeder

connector

securing

knob.

2-4.

CHANGING

CONTACT

TUBES

AND

WIRE

SIZES

(Figure

2-1)

-

Each

time

the

size

of

the

elec

trode

wire

being

used

is

changed,

it

will

be

necessary

to

change

the

contact

tube,

the

outlet

wire

guide,

and

the

inlet

wire

guide

to

permit

proper

movement

of

the

elec

trode

wire.

(For

instructions

on

installing

the

inlet

wire

guide,

consult

the

Owners

Manual

for

the

appropriate

wire

feeder).

When

changing

from

3/32,

7/64,

or

1/8

to

.045,

1/16,

or

5/64

wire,

the

two

piece

monocoil

liner

must

be

changed

to

a

one

piece

liner

and

a

rear

center

ing

sleeve

must

be

added.

S

OM-1519

Page

1

IMPORTANT

proper

components.

IMPORTANT

IMPORTANT

Outlet

Wire

Guide

~~Mono:oii

Rear

Monocoil

Centering

Sieeve

Screw

B-080

859

When

changing

from

.045,

1/16,

or

5/64,

to

3/32,

7/64

or

1

/8

wire,

the

one

piece

monocoil

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

the

end

of

the

contact

tube.

liner

must

be

changed

to

a

two

piece

liner

and

the

rear

centering

sleeve

must

be

removed.

3.

Retract

the

remaining

electrode

wire

onto

the

wire

spool.

When

changing

from

1/16

or

5/64

to

.045

wire

(or

vice

versa),

only

the

monocoil

liner

must

be

changed.

4.

Remove

the

contact

tube.

Refer

to

the Parts

List

to

determine

5.

Disconnect

the

gun

assembly

from

the

con

trol/feeder.

Whenever

the

electrode

wire

size

is

6.

Remove

the

outlet

wire

guide

from

the

changed,

blow

out

both

the

monocoil

liner

and

gun/feeder

connector.

monocoil

casing

with

compressed

air.

7.

If

only

the

contact

tube

and

the

outlet

wire

guide

A.

Changing

The

Contact

Tube

require

changing

proceed

to

Step

18.

1.

Remove

the

nozzle.

8.

Loosen

the

monocoil

set

screws

on

the

gun

han

dle

and

the

gun/feeder

connector

insulator.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

the

end

of

the

contact

tube.

The

iwo-piece

monocoil

liners

used

for

3/32

7/64

or

1/8

wire

can

be

inserted

or

3.

Remove

the

contact

tube

and

replace

with

ap-

removed

from

their

respective

ends

without

the

removal

propriate

contact

tube.

of

the

head

tube.

4.

Replace

the

nozzle

and

resume

operation.

9.

Pull

out

and

remove

the

monocoil

liner

from

the

.

B.

Changing

Wire

Sizes

gun/feeder

connector

end

of

the

gun

assembly.

1.

Remove

the

nozzle.

10.

If

the

rear

centering

sleeve

does

not

require

changing

proceed

to

Step

15.

Nozzle

Head

Tube

Gun

Trigger

Clamp

Monocoil

Set

Screw



Gun

Handle

Shielding

Gas

Connector

Plug

Figure

2-1.

Gun

Components

Page

2

11.

Slide

the

insulator

off

of

the

gun/feeder

connec-

17.

Tighten

the

monocoil

liner

set

screws.

Do

not

tor

to

gain

access

to

the

centering

sleeve

set

over-tighten

the

set

screws

as

this

may

crush

the

screw.

monocoil.

12.

Loosen

the

centering

sleeve

set

screw.

18.

Install

the

new

contact

tube.

19.

Replace

the

nozzle.

20.

Install

the

new

outlet

wire

guide.

13.

Add

or

remove

the

rear

centering

sleeve

as

necessitated

by

the

wire

size

change.

When

ad

ding

the

rear

centering

sleeve,

insert

the

center

ing

sleeve

into

the

gun/feeder

connector;

rotate

the sleeve

until

the

notched

portion

lines

up

with

the

monocoil

set

screw

hole;

and

secure

the

centering

sleeve

set

screw.

14.

Reposition

the

insulator

over

the

gun/feeder

connector.

15.

Draw

the

gun

out

flat

(no

coils

in

the

cable/con

duit).

16.

Insert

the

new

monocoil

liner(s).

IMPORTANT

The

new

monocoil

liner

will

be

longer

than

necessary.

Cut

off

the

excess

liner

flush

with

the

outlet

wire

guide.

Deburr

the

liner

if

necessary.

21.

Make

gun

connections

as

instructed

in

Sections

2-1,2-2,and2-3.

22.

Thread

new

size

electrode

wire

and

resume

operation.

OM-1519

Page

3

December

1980

FORM:

OM-151~

PARTS

LIST

1

Figure

A



Exploded

View

Of

Gun

Assembly

TC-O8O

858

3

4

5

7

35

34

33

9

41

25

19

18

1

23

24

16

14

40

21

26

OM-1519

Page

1

Figure

A

Exploded

View

Of

Gun

Assembly

2

2

2

2

2

2

3

4

5

6

7

8

9

10

10

11

11

12

13

14

15

16

17

18

19

19

19

19

19

19

20

20

21

21

22

23

24

25

26

26

27

28

29

075

659

NOZZLE,

screw

type

5/8

orifice

15/16

ID

x

2-3/8

t008

620

NOZZLE,

screw

type

1-3/16-16

x

2-3/8

long

NOZZLE,

spot

-

flat

2-5/8

long

NOZZLE,

spot

-

inside

2-5/8

long

NOZZLE,

spot

-

outside

3-1/8

long.

NOZZLE,

15/16

orifice

2-3/8

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

ADAPTER,

nozzle

WASHER,

flat

-

silicon

0.930

OD

TUBE,

head

(consisting

of)

INSULATOR,

centering

-

head

tube

-

LINER,

moriocoil

3/32-1/8

wire

x

7-3/8

HANDLE,

gun

SCREW,

machine

-

steel

flat

hd

1/4-20x

3/8

HOSE,

gas

10

ft.

(consisting

of)

HOSE,

gas

15

ft.

(consisting

of)

HOSE,

neoprene

No.

1

3/16

ID

(order

by

ft.)

604 550

.

HOSE,

neoprene

No.

1

3/16

ID

(order

by

ft.)

010606

.

FITTING,

hose-brass

nut

5/8-18

RH.

010

603

.

FITTING,

hose

-

brass

barbed

nipple

1/4TBG

007

500

SPRING,

compression

079

021

SCREW,

set

-

steel

socket

hd

3/8-16x1/2

076

051

INSULATOR,

adapter

gun/feeder

605

789

SCREW,

set

-

steel

socket

hd

10-24

x

1/4

079

856

SLEEVE,

centering

-

monocoil

053

722

LINER,

monocoil

0.045

wire

10

ft.

053

721

LINER,

rnonocoil

0.045

wire

15

ft.

059

063

LINER,

monocoil

1/16-5/64

wire

10

ft.

059

064

LINER,

monocoil

1/16-5/64

wire

15

ft.

007

594

LINER,

monocoil

3/32-1/8

wire

10

ft.

007

595

LINER,

monocoil

3/32-1/8

wire

15

ft.

079

852

GUIDE,

wire

-

outlet

0.045-5/64

wire..

079

851

GUIDE,

wire

-

outlet

3/32-1/8

wire

079

860

CABLE,

conduit 10

ft.

(consisting

of)

-

079

859

CABLE,

conduit 15

ft.

(consisting

of)

-

048

825

.

ADAPTER,

gun/feeder

004

733

-

CLAMP,

cable

-

conduit

004

732

.

CLAMP,

cable

-

conduit

005

589

.

BODY,

gun

079 855

CORD,

power

10

ft.

(consisting

of)

079

854

CORD,

power

15

ft.

(consisting

of)

079

878

-

HOUSING,

plug

-

plastic

(consisting

of)

079

535

..

TERMINAL,

male

1

pin

048

834

-

CLAMP,

cable

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

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

10

ft.

10

ft.

10

ft.

10

ft.

lOft.

10

ft.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

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 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

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

2

2

2

2

2

2

1

1

1

1

1 1

I

tern

No.

Factory

Part

No.

Quantity

M

nrl

~1

Description

,

lOFT

-

And

-

15FT

1.2MM

.047

1.6MM

.063

2.0MM

12.4MM

I

2.8MM

I

3.2MM

.079

.094

.110

.126

.045

1/16

5/64

~,

/327~64~J

1/8

t075

662

t075

663

t075

665

t075

660

075

613

075

614

075

615

075

616

075

617

075

618

075

948

073

777

076

173

076

130

008

057

076

175

078

894

056

462

056

542

604

550

1

1

1

1

1

1

1

1

1

OM-1519

Page

2

604

525

.

CORD,

portable

No.

18

2/C

(order

by

ft.)

.SWITCH,Iicon

SPRING,

compression



STRAIN

RELIEF,

cable



BLOCK,

mounting

-

switch



LEVER,

actuating

-

switch



NUT,

speed

-

push

-

on

0.32

ID

x

7/16

OD



RIVET,

steel

-

solid

flat

hd

7/32dia.x

1-1/4

long



HOUSING,

switch

.CLAMP,

hose

0.66-1-3/4

clamp

dia..

CLAMP,

strap

-

rubber

5

holes

10

ft.

-

CLAMP,

strap

-

rubber

5

holes

15

ft.

SCREW,

set

-

steel

socket

hd

1/4-20x1/4

lOFT

-

....~.

15FT

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

1

1

1

1 1

1

1

1

1

10

10

10

10

10

10

15

15

15

15

15 15

1 1

1

1

1 1

The

Following

Parts

Are

Required

To

Change

The

Gun

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.

1.2MM

.047

.045

Quantity

Model

lOFT

And

1.6MM

2.0MM

2.4MM

.063

.079

.094

1/16

5/64

3/32

15

FT

2.8MM

.110

7/64

x

x

x

x

x x

Item

Factory

Quantity

Model

~

nrl

1.2MM

.047

.045

1.6MM

.063

1/16

No.

Part

No.

Description

Figure

A

Exploded

View

Of

Gun

Assembly

(Contd.)

2.0MM

2.4MM

2.8MM

.079

.094

.110

5/64 3/32

7/64

3.2MM

.126

1/8

30

31

32

33

34

35

36

37

38

39

40

40

41

*

604 866

059

294

053

132

059

258

057

171

059

290

059

293

056

845

010

497

073

476

073

476

602

177

*

*

Description

3.2MM

.126

1/8

2

075613

2

075614

2

075615

2

075616

2

075617

2

075618

2

044

384

7

008057

17

605789

18

079856

19

053722

19

053721

19

059063

19

059064

19

007594

19

007595

20

079

852

20

079851

*As

Required.

TUBE,

contact

.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

TUBE,

contact

.052

wire

LINER,

monocoil

3/32-1/8

wire

x

7-3/8

SCREW,

set

-

steel

socket

hd

10-24

x

1/4

SLEEVE,

centering

-

monocoil

LINER,

monocoil

.045

wire

10

ft

LINER,

monocoil

.045

wire

15

ft

LINER,

monocoil

1/16-5/64

wire

10

ft

LINER,

monocoil

1/16-5/64

wire

15

ft

LINER,

monocoil

3/32-1/8

wire

10

ft

LINER,

monocoil

3/32-1/8

wire

15

ft

GUIDE,

wire

-

outlet

.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

x

x

x

x

x

x

x

x

tOptional

Equipment.

BE

SURE TO

PROVIDE

MODEL

WHEN

ORDERING

REPLACEMENT

PARTS.

x

x

x

Page

3

January

1979

FORM:

OM-1519

FLE

COPY

RETURN

TO

FOLDEi~

OWN

ERS

MANUAL

HilliER

~1k~

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

20

CENTS

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

MODEL

GA-50C

L~P

~

~

~

1

LIMITED

WARRANTY

EFFECTIVE:

JANUARY

I,

1979

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

conditions

As

a

matter

of

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

to

submitted

by

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

d

by

Miller

is

free

from

defect

in

workmanship

and

material

as

of

the

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

time

and

place

of

delivery

by

Miller.

No

warranty

is

made

by

Miller

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefor

shall

be,

at

Millers

option,

(I)

repair

or

(2)

replacement

or,

with

respect

to

engines,

trade

accessories

or

other

items

manu-

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

the

factured

by

others.

Such

engines,

trade

accessories

and

other

items

are

sold

subject

to

the

warranties

of

their

respective

manu-

reasonable

Cost

of

repair

or

replacement

at

an

authorized

Miller

ser

facturers,

if

any.

At

the

present

time,

the

manufacturers

warranty

on

vice

station

or

(4)

payment

of

or

credit

for

the

purchase

price

(less

the

Mag-Diesel

engine

on

DEL-200

is

limited

to

six

months

and

~

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

all

other

engines

to

one

year.

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

Except

as

specified

below,

Millers

warranty

does

not

apply

to

warranty

claim

procedures

to

be

followed.

components

having

normal

useful

life

of

less

than

one

(1)

year,

such

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

as

spot

welder

tips,

relay

and

contactor

points,MILLERMATIC

parts

ANY

IMPLIED

WARRANTY

GUARANTY

OR

REPRESENTA

~

that

come

in

contact

with

the

welding

wire

including

nozzles

and

TION

AS

TO

PERFORMANCE,

AND ANY

REMEDY

FOR

nozzle

insulators

where

failure

does

not

result

from

defect

in

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

~

workmanship

or

material.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUS-



TOM

OF

TRADE

OR

COURSE

OF

DEALING

INCLUDING

ANY

Miller

shall

be

required

to

honor

warranty

claims

on

warranted

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OROF

FITNESS

~

Equipment

in

the

event

of

failure

resulting

from

a

defect

within

the

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY AND

following

periods

from

the

date

of

delivery

of

Equipment

to

the

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

original

user:

AND

DISCLAIMED

BY

MILLER.

I.

Arc

welders,

power

sources

and

components

.

.

.

I

year

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

WRIT-

(labor

-

1

year

only)

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

2.

Original

main

power

rectifiers

3

years

ING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

3.

All

welding

guns

and

feeder/guns

90

days

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

4.

All

other

Millermatic

Feeders

1

year

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor

.

:

60

days

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLER

WAR

6.

Batteries

.

6

months

RANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

provided

that

Miller

is

notified

in

writing

within

thirty

(30)

days

of

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO,

the

date

of

such

failure.

ANY

CONSUMER.

-

~

~%

SECTION

1

-

INTRODUCTION

Rating:

100

PCT.

-

Wire

Cable

and

Duty

Cycle,

dcrp

Dia.

Hose

Length

500

Amperes

.045

(1.1

mm)To

10

With

CO2

1/8

(3.1

mm)

Flux

Cored

15

Net

Ship

Weight

Weight

15

Lbs.

(6.8

Kilos)

17

Lbs.

(7.6

Kilos)

17

Lbs.

(7.6

Kilos)

19

Lbs.

(8.6

Kilos)

1-1.

GENERAL

Figure

1-1.

Specifications

This

manual

has

been

prepared

especially

for

use

in

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

of

this

equipment.

All

informa

tion

presented

herein

should

be

given

careful

consideration

to

assure

optimum

performance

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

and

freight

bill

will

be

furnished

by

the

carrier

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equipment,

it

is

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

CAUTION

Under

this

heading,

installation,

oper

~g,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

hazard

to

per



sonnel.

1TA~1

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result

in

damage

to

equip

-

~

I

1-3.

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

.045,

1/16,

5/64.

3/32,

7/64,

or

1/8

wire,

1-4.

SAFETY

The

following

definitions

apply

to

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

NOTE

1

Under

this

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the

most

efficient

operation

of

the

equipment.

SECTION

2

-

INSTALLATION

.

Prior

to

installing

the

gun,

ensure

that

the

control/

feeder

and

welding

power

source

are

both

completely

disconnected

from

the

respective

input

electrical



power

supplies.

2-1.

SHIELDING

GAS

CONNECTION

(Figure

2-1)

Connect

the

gas

hose

from

the

gun

to

the

gas

connector

from

the

control/feeder,

The

shielding

gas

connector

has

right-

hand

threading.

2-2.

GUN

SWITCH

CONNECTIONS

Align

the

keyway

and

insert

the

amphenol

gun

Switch

Connector

into

the

switch

control

receptacle.

Rotate

the

connector

collar

clockwise

to

lock

the

connector

in

the

receptacle.

2-3.

GUN/FEEDER

ADAPTER

CONNECTION

Install

the

gun/feeder

adapter

into

the

drive

assembly

as

follows:

1.

Loosen

the

outlet

guide

adjustable

knob.

2.

Insert

the

gun/feeder

adapter

into

the

hole

provided

in

the

drive

assembly

opposite

the

inlet

wire

guide.

3,

Tighten

the

Outlet

guide

adjustable

knob.

2-4.

CHANGING

CONTACT

TUBES

AND

WIRE

SIZES

(Figure

2-1)

Each

time

the

size

of

the

electrode

wire

being

used

is

changed,

it

will

be

necessary

to

change

the

contact

tube,

the

outlet

wire

guide,

and

the

inlet

wire

guide

to

permit

proper

movement

of

the

electrode

wire.

(For

instructions

on

installing

the

inlet

wire

guide,

consult

the

Owners

Manual

for

the

appropriate

control/feeder).

When

changing

from

3/32, 7/64,

or

1/8

to

.045,

1/16,

or

5/64

wire,

the

two

piece

monocoil

liner

must

be

changed

to

a

one

piece

liner

and

a

rear

centering

sleeve

must

be

added.

When

changing

from

.045,

1/16,

or

5/64.

to

3/32,

7/64

or

1/8

wire,

the

one

piece

monocoil

liner

must

be

changed

to

a

two

piece

liner

and

the

rear

centering

sleeve

must

be

removed.

When

changing

from

1/16

or

5/64

to

.045

wire

(or

vice

versa),

only

the

monocoil

liner

must

be

changed.

E~EJ

Refer

to

the

Parts

List

to

determine

proper

compo



nents.



TA7~

Whenever

the

electrode

wire

size

is

changed,

blow

out

both

the

monocoil

liner

and

monocoil

casing

with



compressed

air.

A.

Changing

The

Contact

Tube

1.

Remove

the

nozzle.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

the

end

of

the

contact

tube.

3.

Remove

the

contact

tube

and

replace

with

appropriate

contact

tube.

4.

Replace

the

nozzle

and

resume

operation.

Cooling

Method

Air

Air

OM-1519

Page

1



The

two-piece

monocoil

liners

used

for

3/32,

7/64,



or

1/8~

wire

can

be

inserted

or

removed

from

their

i

respective

ends

without

the

removal

of

the

head

tube.



9.

Pull

out

and

remove

the

monocoil

liner

from

the

gun/feeder

adapter

end

of

the

gun

assembly.

10.

If

the

rear

centering

sleeve

does

not

require

changing

proceed

to

Step

15.

11.

Slide

the

insulator

off

of

the

gun/feeder

adapter

to

gain

access

to

the

centering

sleeve

set

screw.

21.

Make

gun

connections

as

instructed

in

Sections

2-1,

2-2.

and

2-3.

22.

Thread

new

size

electrode

wire

and

resume

operation.

Figure

2-1.

Gun

Components

B.

Changing

Wire

Sizes

1.

Remove

the

nozzle.

2.

Cut

off

any

portion

of

the

electrode

wire

which

extends

beyond

the

end

of

the

contact

tube.

3.

Retract

the

remaining

electrode

wire

onto

the

wire

spool.

4.

Remove

the

contact

tube.

5.

Disconnect

the

gun

assembly

from

the

control/feeder.

6.

Remove

the

outlet

wire

guide

from

the

gun/feeder

adapter.

7.

If

only

the

contact

tube

and

the

outlet

wire

guide

require

changing

proceed

to

Step

18.

8.

Loosen

the

monocoil

set

screws

on

the

gun

handle

and

the

gun/feeder

adapter

insulator.

12.

Loosen

the

centering

sleeve

set

screw.

13.

Add

or

remove

the

rear

centering

sleeve

as

necessitated

by

the

wire

size

change.

When

adding

the

rear

centering

sleeve,

insert

the

centering

sleeve

into

the

gun/feeder

adapter;

rotate

the

sleeve

until

the

notched

portion

lines

up

with

the

monocoil

set

screw

hole;

and

secure

the

centering

sleeve

set

screw.

14.

Reposition

the

insulator

over

the

gun/feeder

adapter.

15.

Draw

the

gun

out

flat

(no

coils

in

the

cable/conduit).

16.

Insert

the

new

monocoil

liner(s).

17.

Tighten

the

monocoil

liner

set

screws.

Do

not

over-

tighten

the

set

screws

as

this

may

crush

the

monocoil.

18.

Install

the

new

contact

tube.

19.

Replace

the

nozzle.

20.

Install

the

new

outlet

wire

guide.

mon

ocoil

liner

II

be

Ion

ger

th

an

n

ecessa

ry.

Cut

off

the

excess

liner

flush

with

the

outlet

wire



guide.

Deburr

the

liner

if

necessary.

Contact

Tube

Head

Tube

Outlet

Wire

Guide

Monocoll

Liner

Cable/Conduit

Switch

8-080

859

Page

2

January

1979

FORM:

OM-1519

PARTS

LIST

MODEL

GA-50C

1

Figure

A



Exploded

View

Of

Gun

Assembly

TC-O8O

858

r

3

.4

37

38

39

5

7

35~

34

33

9

41

25

19

23

I

O~%~

21

26

OM-1519

Page

1

075

659

NOZZLE,

screw

type

5/8

orifice

15/16

ID

x

2-3/8

t008

620

NOZZLE,

screw

type

1-3/16-16

x

2-3/8

long

NOZZLE,

spot

-

flat

2-5/8

long

NOZZLE,

spot

-

inside

2-5/8

long

NOZZLE,

spot,

outside

3-1/8

long.

NOZZLE,

15/16

orifice

2-3/8

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

ADAPTER,

nozzle

WASHER,

flat

-

silicon

0.930

OD

TUBE,

head

(consisting

of)

INSULATOR,

centering

-

head

tube

LINER,

monocoil

3/32-1/8

wire

x

7-3/8

HANDLE,

gun

SCREW,

machine

-

steel

flat

hd

1/4.20x3/8

HOSE,

gas

10

ft.

(consisting

of)

HOSE,

gas

15

ft.

(consisting

of)

HOSE,

neoprene

No.

1

3/16

ID

(order

by

ft.)

604

550

-

HOSE,

neoprene

No.

1

3/16

ID

(order

by

ft.)

010

606

.

FITTING,

hose

-

brass

nut

5/8-18

RH

010

603

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 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

lOft.

lOft. lOft.

lOft.

lOft.

lOft.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

15

ft.

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

1

1

1 1 1

1

1 1

1

1

1

2

2 2

2 2 2

2

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

2

2

2

2

2

2

1 1

1 1

1

1

OM-1519

Page

2

Figure

A

Quantity

MMeI

Item

No.

Factory

Part

No.

Description

1.2MM

.047

.045

1.6MM

I

2.0MM

1

2.4MM

.063

.079

I

.094

1/16~L5/64

L

3/32

2.8MM

.110

7/64

3.2MM

.126

1/8

10

FT

Ann

15FT

Exploded

View

Of

Gun

Assembly

t075

662

t075

663

t075

665

t075

660

075

613

075

614

075

615

075

616

075

617

075

618

075 948

073

777

076

173

076

130

008

057

076

175

078

894

056

462

056

542

604

550

2

2

2

2

2

2

3

4

5

6

7

8

9

10

10

11

11

12

13

14

15

16

17

18

19

19

19

19

19

19

20

20

21

21

22

23

24

25

26

26

27

28

29

1

1

1

1

1

1

1

1

1

1

1

1

FITTING,

hose

-

brass

barbed

nipple

1/4TBG

007

500

SPRING,

compression

079

021

SCREW,

set

-

steel

socket

hd

3/8-16x1/2

076

051

INSULATOR,

adapter

gun/feeder

605

789

SCREW,

set

-

steel

socket

hd

10-24

x

1/4

079

856

SLEEVE,

centering

-

monocoil

053

722

LINER,

monocoil

0.045

wire

lOft.

053

721

LINER,

monocoil

0.045

wire

15

ft.

059063

LINER,

monocoil

1/16.5/64

wire

10

ft.

059

064

LINER,

monocoil

1/16-5/64

wire

15

ft.

007

594

LINER,

monocoil

3/32-1/8

wire

lOft.

007

595

LINER,

monocoil

3/32-1/8

wire 15

ft.

-

079

852

GUIDE,

wire-

outlet

0.045-5/64

wire..

079

851

GUIDE,

wire

-outlet

3/32-1/8

wire

079

860

CABLE,

conduit

10

ft.

(consisting

of)

079

859

CABLE,

conduit

15

ft.

(consisting

of)

079

857

-

ADAPTER,

gun/feeder

004

733

.

CLAMP,

cable

-

conduit

004

732

.

CLAMP,

cable

-

conduit

005

589

-

BODY,

gun

079

855

CORD,

power

10

ft.

(consisting

of)

079

854

CORD,

power

15

ft.

(consisting

of)

.

079

878

-

HOUSING,

plug

-

plastic

(consisting

of)

079

535

.

.

TERMINAL,

male

1

pin

079

531

-

CLAMP,

cable

1

1

1

1

Figure

A

Exploded

View

Of

Gun

Assembly

(Contd.)

604

525

.

CORD,

portable

No.

18

2/C

(order

by

ft.)



SWITCH,

licon

SPRING,

compression

STRAIN

RELIEF,

cable



BLOCK,

mounting

-

switch

LEVER,

actuating

-

switch

NUT,

speed

-

push

-

on

0.32

ID

x

7/16

OD

RIVET,

steel

-

solid

flat

hd

7/32dia.x

1-1/4

long

HOUSING,

switch

.CLAMP,

hose

0.66-1-3/4

clamp

dia

CLAMP,

strap

-

rubber

5

holes

10

ft.

CLAMP,

strap-

rubber

5

holes

15

ft.

SCREW,

set

-

steel

socket

hd

1/4-20x

1/4

*

*

*

*.

*

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

1

1

1

1

1 1

1

1

1

10

10 10

10

10

10

15 15

15

15

15

15

1

1

1

1

1

1

The

Following

Parts

Are

Required

To

Change

The

Gun

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.

1.2MM

.047

.045

x

x

x

x

x

x

x

x x

x

x

15

FT

2.8MM

.110

7/64

Item

No.

Factory

Part

No.

Quantity

Model

Description

.

And

15FT

______1..Q

FT

1.2MMfiT6MM

2.0MM

2.4MM

.047

.063

.079

.094

.045

1/16

5/64

3/32

2.8MM

.110

7/64

3.2MM

.126

1/8

30

31

32

33

34

35

36

37

38

39

40

40

41

604

866

059

294

053

132

059

258

057

171

059

290

059

293

056 845

010

497

073

476

073

476

602

177

Description

Quantity

Model

lOFT

And

1.6MM

2.0MM

2.4MM

.063

.079

.094

1/16

5/64

3/32

x

3.2MM

.126

1/8

x

2

075613

2

075614

2

075615

2

075616

2

075617

2

075618

7

008057

17

605789

18

079856

19

053722

19

053721

19

059063

19

059064

19

007594

19

007595

20

079 852

20

079851

*As

Required.

x

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

LINER,

monocoil

3/32-1/8

wire

x

7-3/8

SCREW,

set

-

steel

socket

hd

10-24

x

1/4

SLEEVE,

centering

-

monocoil

LINER,

monocoil

0.045

wire

10

ft

LINER,

monocoil

0.045

wire

15

ft

LINER,

monocoil

1/1

6-5/64

wire

10

ft

LINER,

monocoil

1/16-5/64

wire

15

ft

LINER,

monocoil

3/32-1/8

wire

lOft

LINER,

monocoil

3/32-1/8

wire

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

x

x

tOptional

Equipment.

BE

SURE

TO

PROVIDE

MODEL

WHEN

ORDERING

REPLACEMENT

PARTS.

Page

3

Page is loading ...

Page is loading ...

/

Related papers

Other documents