Miller JA000000 Owner's manual

JA000000
Miller
Brand
Miller
Model
JA000000
Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
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
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Miller JA000000 Owner's manual

JA000000
Miller
Brand
Miller
Model
JA000000
Category
Welding System
Type
Owner's manual
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