Millerfi
September
1989
FORM:
OM-1535A
Effective
With
Style
No.
JG-46
MODEL:
GA-40C
GA-4OCAL
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.
Company
P.O.
Box
1079
AppTeton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and unused
Equipment
fur
nished
by
MiUeris
free
from
defectin
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
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
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
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
dutywith
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
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
orcreditforthe
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repairorreplacementwill
be
F.O.B.,
Factory
atAppleton,
Wisconsin,
or
F.O.
B.
at
a
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
daimant
on
the
war
ranty
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
FORTHIS
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
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
COMMERCIAUINDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
r_
ERRATA
SHEET
April
3,
1990
FORM:
OM-1535A
ALE
Copy
RETURN
TO
FOLDER
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
6
PARTS
LIST
Amend
Parts
List
as
foliows:
Quantity~
Part
Replaced
Model
No.
With
Description
GA-40C
9-20
047 574
133
852
CONNECTOR,
cable
feeder
end
(Elf
w/KA-09)
9-26
047 564
133
851
FITTING,
hose
gas
(Elf
w/KA-09)
9-
133
853
CLAMP,
cable/fitting
(Elf
w/KA-09)
9-36
047
575
133
850
CONNECTOR,
cable
gun
end
(Elf
w/KA-09)
1
2
2
1
OM-1535A-
9/99
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
deliverIng
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_______________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
INTRODUCTION
2-1
.
Duty
Cycle
1
2-2.
Description
1
SECTION
3INSTALLATION
3-1.
Gun/Wire
Feeder
Connections
2
3-2.
Gun
Trigger
Connection
2
3-3.
Repositioning
Head
Tube
3
SECTION
4
SEQUENCE
OF
OPERATION
4-1.
Gas
Metal
Arc
Welding
(GMAW)
3
4-2.
Shutting
Down
4
SECTION
5
MAINTENANCE
5-1.
Inspection
And
Upkeep
4
5-2.
Contact
Tube
Replacement
4
5-3.
Cleaning
Monocoil
Liner
4
5-4.
Changing
Wire
Sizes,
Converting
To
Aluminum
Wire,
Or
Replacing
Liners
5
5-5.
Changing
The
Head
Tube
6
5-6.
Recommendations
For
Welding
With
Aluminum
Wire
6
SECTION
6
PARTS
LIST
Figure
6-1.
Exploded
View
Of
GA-40C
Gun
8
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source
in
the
welding
power
source
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
ideri
tify
different
levels
of
hazard
and
special
instructions.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atteri
tion
to
the
safety
statements.
a
a
WARNING
statements
identify
procedures
cr
practices
which
must
be
followed
to
avoid
sen
ous
personal
injury
or
loss
of
life.
CAUTION
statements
identify
procedures
cr
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2INTRODUCTION
Table
2-1.
SpecIfications
Ampere
Rating
600o
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
Ship
400
An~eres
With
02
.035
to
5/64
in.
(0.9
to
2.0
mm)
Hard,
Flux
Cored,
Or
Aluminum
Wire
10
ft.
(3.0
m)
Air
8-1/4
lbs.
(3.8
kg)
9-3/4
lbs.
(4.4
kg)
15
ft.
(4.6
m)
11-3/4
lbs.
(5.3
kg)
13-1/4
lbs.
(6
kg)
2-1.
DUTY
CYCLE
The
duty
cycle
of
a
welding
gun
is
the
percentage
of
aten
minute
period
that
a
gun
can
be
operated
at
a
given
out
putwithoutoverheating
and
damaging
the
gun.
This
gun
is
rated
at
60%
duty
cycle
using
CO2
shielding
gas.
This
means
the
gun
can
be
operated
at
400
amperes
for
six
minutes
out
of
ten
with
C02
shielding
gas.
During
the
re
maining
four
minutes,
the
gun
must
operate
at
no
load
to
permit
proper
cooling.
If
rated
amperage
is
exceeded,
the
duty
cycle
must
be
reduced.
a
CAUTION:
EXCEEDING
THE
RATED
AM
PERAGE
OR
DUTY
CYCLE
can
result
In
dam
age
to
the
gun.
Do
not
exceed
rated
amperage
or
duty
cycle.
2-2.
DESCRIPTION
This
gun
is
specifically
for
use
with
the
Gas
Metal
Arc
Welding
(GMAW)
process
and
hard
cored,
flux
cored,
or
aluminumwire.
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
A
Air
Cooled
40
Ampere
Rating:
400
Amperes
C
Curved
Head
Tube
AL
Aluminum
OM-1535
Page
1
SECTION
3-INSTALLATION
Ring
TC-044
406-A
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
installing,
or
working
on
gun.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removingfusesfromfuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
3-1.
GUN/WIRE
FEEDER
CONNECTIONS
(Figure
3-1)
Install
the
gun/feeder
connector
into
the
drive
assembly
on
the
wire
feeder
as
follows:
IMPORTANT:
The
wire
outlet
guide
is
pro
videdas
part
of
the
gun
assembly.
1.
Loosen
the
gun/feeder
connector
securing
knob
on
the
wire
drive
assembly.
IMPORTANT:
Wire
guides
should
be
positioned
as
close
as
possible
to
the
drive
rolls
without
touching
them.
This
gives
wire
maximum
column
strength.
2.
Insert
gun
into
wire
drive
assembly
until
gun/feeder
connector
stops
against
wire
drive
assembly.
3.
Tighten
gun/feeder
connector
securing
knob.
3-2.
GUN
TRIGGER
CONNECTION
(Figure
3-1)
Connect
gun
trigger
connector
into
TRIGGER
recepta
cle
on
wire
feeder
as
follows:
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
Head
Tube~
Tubing
Cable
Connectc~r
pin
Monocoil
Liner
Setscrew
Trigger
SprIng
Contact
Tube
Adapter
Insuiator
Nut
Gun/Feeder
Connector
Strain
Relief
Handle,
Bottom
Half
Monocofl
Liner
Setscrew
Locking
Ring
Locking
Ring
Figure
3-1.
Gun
Components
OM-1535
Page
2
3-3.
REPOSITIONING
HEAD
TUBE
(Figure
3-1)
The
gun
is
shipped
with
the
head
tube
positioned
as
il
lustrated
in
Figure
3-1.
The
head
tube
can
be
reposi
tioned
by
following
the
procedure
outlined
in
Steps
1-9.
1.
Loosen
head
tube
setscrew
in
gun
handle.
2.
Remove
liner
setscrew.
3.
Remove
pin
and
locking
ring
holding
handle
halves
together.
4.
Separate
two
halves
of
gun
handle.
5.
Rotate
head
tube
1800.
Be
sure
that
machined
de
pressions
in
head
tube
are
lined
up
with
hole
for
set
screw
and
gun
cavities.
IMPORTANT:
Ensure
that
the
switch
leads
do
not
be
come
twisted
when
the
head
tube
is
rotated.
6.
Replace
liner
setscrew
in
opposite
side
of
handle.
7.
Join
handle
halves
together
and
rotate
locking
ring.
8.
Insert
pin
through
handle
halves
and
switch
lever.
Be
sure
that
switch
spring
is
properly
positioned
in
handle.
9.
Tighten
head
tube
setscrew.
SECTION
4-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL
ARC
WELDING
(GMAW)
f%,
WARNING:
ELECTRIC
SHOCK
can
kill;
4~
MOVING
PARTS
can
cause
serious
Injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
wire
feeder
is
operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
point
gun
to
ward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Do
not
use
near
flammable
material.
Allow
work
and
equipment
to
cool before
handling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
orspot
welding
opera
(ions.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
1.
Install
and
connect
gun
according
to
Section
3.
2.
Be
sure
that
proper
electrical
connections
have
been
made
to
the
welding
power
source
and
the
wire
feeder.
3.
Be
sure
that
the
welding
wire
has
been
properly
threaded
and
that
correct
initial
tensions
have
been
set
on
the
drive
rolls
(refer
to
the
appropriate
Own
ers
Manual).
4.
Be
sure
that
the
proper
shielding
gas
is
connected
to
the
shielding
gas
valve.
5.
Place
the
wire
feed
control(s)
in
the
required
posi
tion
for
the
welding
setup.
6.
Place
the
controls
on
the
welding
power
source
in
the
required
position
for
the
welding
setup
(refer
to
welding
power
source
Owners
Manual).
7.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
8.
Prepare
for
welding
by
connecting
work
clamp
to
clean,
bare
metal
at
workpiece.
9.
Turn
on
the
shielding
gas
supply.
10.
Energize
the
welding
power
source
and
the
wire
feeder
(refer
to
the
respective
Owners
Manual).
IMPORTANT:
When
installing
new
equipment,
or
after
prolongedshutdown,
allowshielding
gas
to
flowcontinu
ously
for
at
least
one
minute
before
welding
to
purge
the
shielding
gas
line.
To
avoid
wasting
wire
while
purging,
open
the
drive
roll
housing.
OM-1535
Page
3
11.
Press
Purge
button
on
the
wire
feeder
(if
applicable)
or
the
gun
trigger
to
purge
the
gas
line.
12.
Close
drive
roll
housing,
and
ad
just
tension
(see
ap
propriate
Owners
Manual).
13.
Press
the
gun
trigger,
and
run
the
welding
wire
out
beyond
the
end
of
the
gas
nozzle.
Cut
the
wire
off
so
it
extends
out
1/4
to
3/8
in.
(6.4
mm
to
9.5
mm)
from
end
of
nozzle.
14.
Set
the
Wire
Speed
control
slightly
higher
than
an
ticipated
wire
speed.
15.
Hold
the
end
of
the
gas
nozzle
approximately
1/2
in.
(12.7
mm)
from
the
workpiece.
16.
Press
the
gun
trigger.
Gas
starts
to
flow,
wire
starts
to
feed,
and
the
arc
will
be
established.
If
the
welding
wire
appears
to
slip,
adjust
drive
roll
tension
accord
ing
to
wire
feeder
Owners
Manual.
17.
After
the
controls
on
the
welding
power
source
and
the
wire
feeder
(if
applicable)
have
been
adjusted
for
normal
operation,
the
welding
power
source
(and
wire
feeder)
will
function
automatically
when
the
gu
trigger
is
pressed.
Releasing
the
gun
trigger
will
ex
tinguish
the
arc
and
cause
the
wire
feed
and
gas
flow
to
stop.
4-2.
SHUTTING
DOWN
1.
Stopwelding.
2.
Turn
off
welding
power
source
and
wire
feeder.
3.
Turn
off
the
shielding
gas
at
its
source.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
5
-
MAINTENANCE
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
4~
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts:
tighten,
repair
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
dirt
that
has
accumulated
around
nozzle
opening
and
inside
nozzle.
3.
Repair
or
replace
as
required
all
hose
and
cables;
give
particular
attention
to
frayed
and
cracked
insu
lation
and
areas
where
it
enters
equipment.
4.
Remove
grease
and
grime
from
components
and
moisture
from
electrical
parts
and
cables.
5.
Blow
out
casingwith
compressed
airwhen
changing
wire.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
~
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
can
injure
personnel
and
damage
equip
ment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
5-2.
CONTACT
TUBE
REPLACEMENT
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wir
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Remove
nozzle.
2.
Cut
off
any
portion
of
electrode
wire
which
extends
beyond
end
of
contact
tube.
3.
Remove
contact
tube,
and
replace
with
new
contact
tube.
4.
Reinstall
nozzle,
and
resume
operation.
5-3.
CLEANING
MONOCOIL
LINER
(FIgure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Periodically,
depending
on
usage
and
conditions,
it
wi
be
necessary
to
clean
the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt
that
may
have
accumu
lated.
To
clean,
proceed
as
follows:
OM-1535
Page
4
1.
Retract
wire
onto
wire
spool.
2.
Disconnect
gun
from
wire
feeder.
3.
Remove
liner
setscrew
from
gun
handle.
4.
Rotate
strain
relief
locking
rings
to
release
and
re
move
rings
from
strain
relief.
5.
Separate
and
remove
strain
relief
halves.
6.
Remove
liner
setscrew
from
gun/feeder
connector.
7.
Lay
cable
out
straight,
and
pull
monocoil
liner
out
from
gun/feeder
connector
end.
a
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
can
injure
personnel
and
damage
equip
ment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
8.
Blow
monocoil
liner
and
casing
out
with
clean,
dry,
compressed
air.
9.
Lay
cable
out
straight.
10.
Insert
monocoil
liner
fully
into
casing.
a
CAUTION:
OVERTIGHTENING
LINER
SET
SCREWS
can
damage
monocoil
liner.
Do
not
overtighten
liner
setscrews.
11.
Tighten
linersetscrews
in
gun
handle
and
gun/feed
er
connector.
12.
Reinstall
strain
relief
valves.
13.
Reinstall
and
rotate
locking
rings
securely
over
strain
relief
valves.
14.
Reinstall
gun,
and
rethread
welding
wire.
15.
Resume
operation.
5-4.
CHANGING
WIRE
SIZES,
CONVERTING
TO
ALUMINUM
WIRE,
OR
REPLACING
LINERS
(Figure
3-1
and
FIgure
5-1)
4A
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
When
changing
the
gun
from
.035
or
.045
in.
(0.9
or
1.1
mm)
wire
to
1/16
or
5/64
in.
(1.6
or
2.0
mm)
wire
or
vice
versa,
or
when
changing
the
gun
to
feed
aluminum
wire,
it
is
necessary
to
change
the
contact
tube,
contact
tube
adapter,
liner,
and
wire
guides
(For
inlet
wire
guide
in
stallation,
referto
the
appropriate
welding
power
source
or
wire
feeder
Owners
Manual).
1.
Remove
nozzle.
2.
Cut
off
any
portion
of
the
electrode
wire
which
ex
tends
beyond
end
of
contact
tube.
3.
Retract
wire
onto
wire
spool
4.
Remove
contact
tube
and
contact
tube
adapter.
5.
Disconnect
gun
assembly
from
wire
feeder,
and
lay
it
out
flat
(no
coils
in
cable/conduit).
6.
Remove
outlet
wire
guide
(see
Figure
3-1).
7.
Loosen
monocoil
liner
setscrew
in
handle.
8.
Pull
out
liner
from
gun/feeder
connector
end
of
gun
assembly.
a
CAUTION:
FLYING
DIRT
AND
METAL
CHIPS
can
Injure
personnel
and
damage
equIp
ment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
9.
Blow
out
gun
casing
or
liner
with
compressed
air
whenever
the
wire
or
liner
is
removed.
10.
Insert
new
liner
into
gun/feeder
connector
end
of
gun
assembly.
11.
Insert
new
outlet
wire
guide.
a
CAUTION:
OVERTIGHTENING
OUTLET
GUIDE
wIll
damage
liner.
Do
not
overtighten
outlet
guide.
12.
Install
gun/feeder
connector
end
of
gun
into
vvire
feeder
and
check
distance
of
end
of
monocoil
linerto
drive
rolls.
Monocoil
liner
should
be
as
close
as
pos
sible
to
drive
rolls
without
touching
(see
Figure
5-1).
13.
Cut
liner
off
so
it
sticks
out
1/4
in.
(6.4
mm)
(3/8
in.
9.5
mm]
for
aluminum)
from
end
of
the
head
tube.
IMPORTANT:
Deburr
liner
to
insure
proper
seating
of
liner
into
adapter.
14.
Install
new
contact
tube
adapter
and
contact
tube.
4A
CAUTION:
OVERTIGHTENING
LINER
SET
SCREW
will
damage
liner.
Do
not
overtighten
liner
setscrew.
15.
Tighten
liner
setscrew
in
gun
handle
to
lock
the
liner
in
place.
Drive.
Rolls
Monocoil
Liner
Outlet
Wire
Guide
TA-ill
091
Figure
5-1.
Monocoll
Liner
And
Drive
Rolls
OM-1
535
Page
5
16.
Reinstall
nozzle.
17.
Make
gun
connections
as
instructed
in
Sections
3-1
and
3-2).
18.
Thread
new
size
electrode
wire.
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
is
pressed.
19.
Resume
operation.
5-5.
CHANGING
THE
HEAD
TUBE
(FIgure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kIll;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Disconnect
gun
assembly
from
wire
feeder.
2.
Remove
the
nozzle,
contact
tube,
contact
tube
adapter,
insulator,
and
nozzle
retaining
nut
from
head
tube.
3.
Remove
monocoil
liner
setscrew.
4.
Loosen
head
tube
setscrew.
5.
Remove
pin
and
locking
ring
holding
the
gun
handle
halves
together.
6.
Separate
the
gun
handle
halves.
7.
Remove
head
tube
from
cable
connector.
8.
Remove
acrylic
glass
tubing
from
heat
tube.
9.
Install
acrylic
glass
tubing
onto
new
head
tube.
10.
Install
new
head
tube
onto
cable
ccnnector.
IMPORTANT:
If
replacing
an
80
head
tube
with
a
60
head
tube
or
a
straight
head
tube,
cut
off
the
existing
lin
er
so
it
sticks
out
3/8
in.
(9.5
mm)
from
the
end
of
the
head
tube.
If
replacing
a
600
ora
straight
head
tube
with
an
80
head
tube,
remove
the
wire
outlet
guide
from
the
gun/feeder
connector.
Remove
and
install
the
liner
as
instructed
in
Section
5-3.
Reinstall
the
outlet
wire
guide.
Cut
the
liner
off
so
it
sticks
out
3/8
in.
(9.5
mm)
from
the
end
of the
head
tube.
11.
Position
cable/conduit
and
head
tube
in
bottom
half
of
gun
handle
with
acrylic
glass
tube
on
top
of
the
leaf
switch
and
the
cable
strain
relief
fitted
into
the
appropriate
groove.
IMPORTANT:
Be
sure
that
the
leaf
switch
is
properly
po
sitioned
in
bottom
half
of
gun
handle
as
illustrated
in
Figure
3-1,
and
the
machined
depression
in
the
head
tube
is
lined
up
with
hole
for
the
head
tube
setscrew.
12.
Join
the
gun
handle
halves
together,
and
securely
rotate
the
locking
ring.
13.
With
switch
spring
properly
positioned
in
gun
handle
(see
Figure
3-1),
insert
pin
through
gun
handle
halves
and
gun
switch.
14.
Tighten
the
head
tube
setscrew.
4~
CAUTION:
OVERTIGHTENING
LINER
SET
SCREW
will
damage
liner.
Do
not
overtighten
liner
setscrew.
15.
Reinstall
monocoil
liner
setscrew
and
tighten.
16.
Reinstall
nozzle
locking
nut,
insulator,
contact
tube,
contact
tube
adapter,
and
nozzle.
5-6.
RECOMMENDATIONS
FOR
WELDING
WITH
ALUMINUM
WIRE
1.
Use
inlet
and
intermediate
guides
(if
applicable)
made
of
nylon
or
teflon.
2.
Use
smooth,
u-groove
type
drive
rolls.
3.
Adjust
drive
roll
pressure
so
that
pressure
is
tight
enough
to
feed
the
wire,
yet
loose
enough
to
allow
drive
rolls
to
slip
on
the
wire
if
a
restriction
occurs.
Proper
pressure
adjustment
will
help
prevent
possi
ble
birdnesting
at
the
drive
rolls.
4.
Cut
off
end
of
electrode
wire
before
making
initial
starts.
Repetitive
starts
that
do
not
allow
the
elec
trode
wire
to
cool
do
not
normally
need
cutting.
5.
Keep
gun
cable
as
straight
as
possible
to
ensure
re
liable
wire
feeding.
OM-1535
Page
6
SECTION
6-
PARTS
LIST
OM-1
535
Page
7
38J
N
Figure
6-1.
Exploded
View
Of
GA-40C
Gun
TC-049
927-F
10
30
21
1~
8
23
Includes
items
28
thru
30
27
19
OM-1535
Page
8
Quantity
Mode
GA-40C
(GA-4OCAi.
Item
No.
Part
No.
Description
Figure
6-1.
Exploded
View
Of
GA-40C
Gun
1
2
047
957
054
183
NOZZLE,
screw
type
5/8
orf
x
2-3/4
TUBE,
contact
.035
wire
1
2
2
054
157
TUBE,
contact
.045
wire
2
2
047566
TUBE,
contact 1/16
wire
2
2
047
565
TUBE,
contact
5/64
wire
2
2
057
730
TUBE,
contact
.052
wire
1
3
094
985
ADAPTER,
tube
contact
.035
-
.045
wire
1
3
094
987
ADAPTER,
tube
contact
1/16
-
5/64
wire
1
3
109
805
ADAPTER,
tube
contact
.047
wire
1
4
094
986
INSULATOR,
nozzle
1
1
5
047
603
NUT,
conduit
1-1/8-18
1
1
6
081
957
SWITCH,
leaf
1
1
7
112
244
NUT,
handle/head
tube
1
1
8
9
089
400
112
097
HANDLE,
gun
SCREW,
set
skt
hd
1/2-13
x
3/8
1
1
1
1
10
11
12
13
14
15
059
294
049
313
047
867
049
872
079 878
079 535
SPRING,
.21
OD
x
5/8
Ig
TRIGGER,
gun
TUBING,
gI
acrylic
No.
9
x
1/2
CABLE,
power
15
in
(consisting
of)
.
HOUSING
PLUG
&
PINS,
(consisting
of)
.
TERMINAL,
male
1
1
1
1
1
4
1
1
1
1
1
4
16
048
834
CLAMP,
cable
strain
relief
sz
11
1
1
17
18
19
604
525
081
909
091
602
CABLE,
port
No.
18
2/c
(order
by
ft)
SPLICE,paraIIel2O-l6wire
STRAIN
RELIEF
2ft
2
1
2ft
2
i
20
047
574
CONNECTOR,
cable
feeder
end
1
1
21
079974
O-RING,1/2lDx.103
2
2
22
047
555
GUIDE,
wire
-
outlet
.045
wire
1
22
047
556
GUIDE,
wire
-
outlet
1/16
-
5/64
wire
1
22
109
797
GUIDE,
wire
-
outlet
.047
1
23
24
25
26
27
28
049312
081
959
049
876
047
564
083
891
079975
RING
locking
SCREW,
set
hollow
lock
6-32
x
3/32
NUT,
connecting
-
cable
FITTING,
hose
-
gas
LINER,
monocoil
.045
wire
(consisting
of)
~O-RlNG,3/16IDx.103
3
2
2
2
1
1
3
2
2
2
29
30
049
307
081
959
.
COLLAR,
1kg
.
SCREW,
set
hollow
lock
6-32
x
3/32
1
1
27
28
29
30
27
28
29
30
31
32
32
33
34
35
36
37
38
083
897
079975
047
557
081
959
109
807
079975
109
799
081
959
112884
047572
047573
049
298
602
173
112096
047
575
049
854
046115
LINER,
monocoil
(consisting
of)
~O-RING,3/16IDx.1O3
.
COLLAR,
1kg
6-32
SCREW,
set
-
hollow
lock
6-32
x
3/32
LINER,
monocoil
(consisting
of)
~O-RlNG,3/16!Dx.103
COLLAR,
1kg
SCREW,
set
-
hollow
lock
6-32
x
3/32
STRAIN
RELIEF,
extension
feeder
end
CABLE/CONDUIT
lOft
or
CABLEJCONDUIT~
l5ft
STRAIN
RELIEF,
extension
cable
end
SCREW,
set
skt
hd
10-32
x
1/4
PIN,spring5/32x1-3/8
CONNECTOR,
cable
gun
end
TUBING,
gI
acrylic
1/2
x
1-1/4
TUBE,head6odeg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For
All
Gun
Lengths
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1535
Page
9
Optional
Equipment
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
No.
Part
No.
Quantity
Model
GA-40C
I
GA-4OCAL
Description
1
044
005
NOZZLE,
spot
flat
1-1/2
ID
x
3-19/32
X
1
046
776
NOZZLE,
spot
flat
1-1/16
ID
x
3-19/32
X
1
046
775
NOZZLE,
spot
inside
corner
1-1/16
ID
x
3-19/32
X
1
046
774
NOZZLE,
spot
outside
corner
1-1/16
tD
x
3-19/32
X
1
045
638
NOZZLE,
screw
type
13/16
orf
x
2-3/4
X
1
047
959
NOZZLE,
screw
type
1/2
orf
x
2-3/4
X
1
071
214
NOZZLE,
tapered
3/4
orf
x
2-?/4
2
054
202
TUBE,
contact
.030
-
.035
wire
x
1-5/16
X
2
054
201
TUBE,
contact
.045
wire
x
1-5/16
X
2
071
212
TUBE,
contact
tapered
.O35wirex
1-7/16
2
071
213
TUBE,
contact
tapered
.O45wirex
1-7/16
2
044
006
TUBE,
contact
.052
wire
x
1-5/16
X
2
057
730
TUBE,
contact
.052
wire
x
1-7/16
X
2
047
576
TUBE,
contact
1/16
wire
x
1-7/16
X
2
047
577
TUBE,
contact
5/64
wire
x
1-5/16
X
38
046
002
TUBE,
head
straight
180
deg
X
38
046
116
TUBE,
head
straight
38
071019
TUBE,head45deg
X
38
046
071
TUBE,
head
80
deg
.035
-
.045
wire
38
046
073
TUBE,
head
80
deg
1/16
-
5/64
wire
045
887
HEAT
SHIELD/HANGING
BRACKET
X
x
x
x
x
x
x
x
x
x
x
OM-1535
Page
10
ACCESSORI
ES
DUAL
SCHEDULE
SWITCHES
For
use
with
RCMP-1,
RCDW-1
and
DDSC
Dual
Schedule
Controls.
DSS-8
For
10
ft.
(3
m)
gun.
Stock
No.
079
691
(Field)
DSS-8
For
15
ft.
(4.6
m)
gun.
Stock
No.
079
693
(Field)
A
two-position
trigger
switch
which
attaches
to
the
gun
handle
and
is
used
in
place
of
the
standard
trigger.
DSS-9
DUAL
SCHEDULE
SWITCH
Stock
No.
071
832
For
10
ft.
(3
m)
gun.
(Field)
Stock
No.
071
833
For
15
ft.
(4.6
m)
gun.
(Field)
A
two-position
slide
switch
which
attaches
to
the
gun
handle
and
is
used
to
select
the
desired
welding
condition.
The
standard
gun
trigger
operates
the
power
supply
contactor.
Note:
Adaptor
cord,
Stock
No.
046
943,
is
required
when
using
a
DSS-8
or
DSS-9
switch
with
an
RCMP-1
or
RCDW-1
control
and
the
S-52A
or
S-54A
and
single
swingarc
wire
feeder
controls.
ADAPTORS
GA-40C
gun
to
MM-b
&
30
Series
wire
feeders.
.035
(0.9
mm)
&
.045
(1.1
mm)
Wire
Stock
No.
047 540
1/16
(1.6
mm)
&
~/64
(2
mm)
Wire
Stock
No.
047
541
GA-40C
gun
to
MM-70A
wire
feeder.
.035
(0.9
mm)
&
.045
(1.1
mm)
wire
Stock
No.
071
243
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
iists
exceptions
to
data
appearing
iater
in
this
manual.
AMENDMENT
TO
SECTION
6
PARTS
LIST
Amend
Parts
List
as
follows:
Quantity
Part
Replaced
Model
**
No.
With
Description
GA-40C
9-20
047
574
133
852
CONNECTOR,
cable
feeder
end
(Elf
w/KA-09)
1
9-26
047 564
133
851
FITTING,
hose
gas
(Elf
w/KA-09)
2
9-
133
853
CLAMP,
cable/fitting
(Elf
w/KA-09)
2
9-36
047
575
133
850
CONNECTOR,
cable
gun
end
(Elf
w/KA-09)
1
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
Miller GA-40C Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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