GA-40C

Miller GA-40C, GA-40CAL, JG46 Owner's manual

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Millerﬁ

September

1989

FORM:

OM-1535A

Effective

With

Style

No.

JG-46

MODEL:

GA-40C

GA-4OCAL

OWNERS

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,

Millers

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

Millers

breach

of

warranty

orany

other

dutywith

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefore

shall

be,

at

Millers

option

(1)

repair

or

(2)

replacement

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

Miller

service

station

or(4)

payment

of

orcreditforthe

purchase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

Customers

risk

and

expense.

MILLERs

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.

MILLERS

WARRANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

MILLERS

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

_______________________________

ers

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

3INSTALLATION

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

Owners

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

2INTRODUCTION

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

Owners

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

ers

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

Owners

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

Owners

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

Owners

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

Owners

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

Owners

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

/

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