Miller GA-17C User manual

June
1989
FORM:
OM-1
028
Millerfi
Effective
With
Style
No.
JK-34
MODEL
GA-17C
OWNERS
MANUAL
IMPORTANT:
Read
and
understand the entire
contents
of
both
this
Miller
Electric
Mfg.Co.
manual
and the
power
source
manual used
with
this
unit,
with
special
AMOe~G,o~oLIaCorn~anv
emphasis
on
the
safety
material
throughout
both
manuals,
before
in-
P0. Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This
unit and
these
instructions
are
for
use
only by
persons
trained
and
experienced
In
the
Appleton,
WI
54912
USA
Tel.
414-734-9821
safe
operation
of
welding equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
PRINTED
IN
U.S.A.
ADDITiONAL
COPY
PRICE
25
CENTS

E
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
rn
This
warranty supersedes
all
previous
MILLER warranties
and
is exclusivewith
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
Miller is
free
from
defect
in
workmanship
andmaterial
as
of
the time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by Miller
with
respect
to
engines,
trade
accessories
or
other
items manufactured
by
others. Such
engines,
trade
ac
cessories and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
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
honor
warranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
90
days
5.
All
other
Millermatic Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive of
labor
60
days
7.
Batteries
6
months
provided
that
Miller
is notified in
writing
within
thirty
(30)
days
of
the
date
of
such failure.
As
a matter
of
general
policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In the
case
of Millers
breach of
warranty
orany
other
duty
with
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
author
ized
Miller
service
station
or
(4)
payment
of
or
credit for
the
pur
chase
price (less
reasonable
depreciation
based
upon
actual
use)
upon
return
of the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Fac
tory
at
Appleton,
Wisconsin,
or
FOB,
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon receipt
of notice of
ap
parent
defect
or
failure,
Miller
shall instruct
the
claimant
on
the
warranty
daim
procedures
to
be
followed.
ANY EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE OF
DEALING,
INCLUDING ANY IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO ANY AND
ALL
EQUIPMENT
FUR
NISHED
BY MILLER
IS EXCLUDED AND DISCLAIMED
BY
MILLER.
EXCEPT AS
EXPRESSLY PROVIDED
BY MILLER IN
WRITING,
MILLER PRODUCTS ARE INTENDED
FOR
ULTI
MATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR OPERATION
BY
PERSONS
TRAINEDAND 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.
J


ERRATA
SHEET
**First
digit
represents
page
no
-
digits following
dash
represent
item
no.
BE
SURE TO PROVIDE MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING REPLACEMENT
PARTS.
II9LE
COpy
R~II
URN
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
follows:
All
Parts
Eff
w/JK732707
Part
Replaced
**
No. With
Descnptuon
Quantity
7-15 605 565
133
147
STRAIN,
relief cable
I
7-16
128
721
133
352
CABLE/CONDUIT,
lOft
1
7-16
128
722
133
353
CABLE/CONDUIT,
l2ft
1
7-16
128
723
133
351
CABLE/CONDUIT,
15ft
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
identify
different
levels of hazard and
special
instruc
tions.
a
This
safety
alert
symbol
is
used with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
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
Ratina
60%
Duty
Cycre
Wire
Diameter

Cable
Length
Coolina
Method
Weight
Net
Ship
170 Amoeres
With
~O2
0.023
-
0.035
in.
(0.6
-
0.9
mm)
lOft.
(3.0
m)
12
ft.
(3.7
m)
15
ft.
(4.6
m)
Air
3.5
lbs.
(1.6
kg)
I
6 lbs.
(2.7
kg)
4
lbs.
(1.8
kg)
I
6.5
lbs.
(3
kg)
4.5
lbs.
(2
kg)
7
lbs.
(3.2
kg)
2-1.
DUTY
CYCLE
The
duty
cycle
of
a
welding
gun
is the
percentage
of
a
ten
minute
period
that
a
gun
can
be
operated
at
a
given
output
without
overheating
and
damaging
the
gun.
This
gun
is rated
at
60%
duty
cycle
using
C02
shielding
gas.
This
means
the
gun
can
be
operated
at
170
amperes
for
six
minutes
out
of
ten
with
C02
shielding
gas.
During
the
remaining
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
WITH
CO2
OR FAILING
TO
RE
DUCE
THE
WELDING
AMPERAGE
OR
DUTY
CYCLE WHEN
USING
A
MIXED
SHIELDING
GAS
can
result
In
damage
to
the
gun.

Do
not
exceed rated
amperage
when
using
CO2.

Operate
at
30%
duty
cycle
when
using
mixed
shielding
gas.
2-2.
DESCRIPTION
This unit
is
an
air-cooled
semiautomatic
Gas
Metal
Arc
Welding
(GMAW)
gun.
The
alpha-numeric designation
refers
to
the
following:
G-Gun
A

Air
Cooled
17Ampere
Rating:
170
Amperes
CCurved
HeadTube
OM-1028
Page
1

SECTION
3-
INSTALLATION
Contact
Tube
Nozzle
Contact Tube
Adapter
Figure
3-1.
Gun
Components
Connector
TB.124
473
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch ilve
electrical
parts.

Shut
down
welding
power
source
and wire
feeder,
and
disconnect
input
power
employing
locko
uttagging
procedures
before
inspecting
or
installing
gun.
Lockout/tagging procedures
consist
of
remov
ing input
power
plug
from
receptacle,
padlock
ing
line
disconnect switch
in
open
position,
re
moving
fuses
from
fuse
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
vided
as
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.
Monocoll
Liner
Trigger
Switch
Gun
Switch
Plug
Wire Outlet
Guide
OM-1028
Page
2

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
SWITCH CONNECTION
(FIgure 3-1)
Connect
gun
trigger
switch into
TRIGGER
receptacle
on
wire
feeder
as
follows:
align keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
SECTION
4-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL
ARC
WELDING
(GMAW)
4A
WARNING: ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
Injury;
IMPROPER AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
Internal
parts.

Do
not
touch
live
electrical
parts.

Do
not
touch
welding
wire
or
any
metal
part
in
contact
with the
wire
while
welding.
The
welding
wire and all metal
parts
in
contact
with
it
carry
wed
output
when
the
gun
switch is
depressed.

Keep
all
covers
and
panels
in
place
while
op
erating.
Warranty
is
void
if
the
welding
power
source
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
toward
any
part
of the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL, SPATTER,
AND
SLAG
can
cause
fire
and
burns.

Watch
forfire.

Keep
a
fire
extinguisher
nearby,
and know
how
to
use
it.

Do
not
use near
flammable
material.

Allow
work
and
equipment
to
coo/before
han
dling.
MAGNETIC
FIELDS
FROM HIGH
CURRENTS
can
affect
pacemaker
operation.

Wearers
should
consult their
doctor
before
going
near
arc
welding,
gouging,
orspot
welding
~operations.
See
Section 1
-
Safety
Rules For
Operation
Of
Arc
Welding
Power
Source
in
welding
power
source
Owners
Manual
for basic
welding
safety
information.
1.
Be
sure
that
proper
electrical
connections
have
been made
to
the
welding
power
source,
and the
wire
feeder.
2.
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).
3.
Be
sure
that the
proper
shielding
gas
is connected
to
the
shielding
gas
valve.
4.
Place
the
wire
feed
control(s)
in
the
required
posi
tion
for the
welding
setup.
5. Place
the controls
on
the
welding
power
source
in
the
required
position
for the
welding
setup
(refer
to
welding
power
source
Owners
Manual).
6.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet with
proper
filter
lens
according
to
ANSI
Z49.1.
7.
Prepare
for
welding
as
follows,
connect
work
clamp
to
clean,
bare
metal
at
workpiece.
8.
Turn
on
the
shielding
gas
supply.
9.
Energize
the
welding
power
source
and
the
wire
feeder
(refer
to
the
respective
Owners
Manual).
IMPORTANT:
When
installing
new
equipment,,
orafter
prolongedshutdown,
allowshielding
gas
to
flowcontinu
ously
forat
least
one
minute
before
welding
to
purge
the
shielding
gas
line. To
avoid
wasting
wire while
purging,
open
the drive roll
housing.
10.
Press
Purge
button
on
the
wire
feeder
(if
applicable)
or
the
gun
switch
to
purge
the
gas
line.
11.
Close
drive
roll
housing,
and
adjust
tension
(see
ap
propriate
Owners
Manual).
12.
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.
13.
Set
the Wire
Speed
control
slightly
higher
than
an
ticipated
wire
speed.
14.
Hold
the
end
of
the
gas
nozzle
approximately
1/2 in.
(12.7
mm)
from
the
workpiece.
15.
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.
OM-1028
Page
3

16.
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
gun
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.
Stop
welding.
2.
Turn off
welding
power
source
and
wire
feeder.
3. Turn
off the
shielding
gas
at
its
source.
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
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.
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
casing
with
compressed
airwhen
changing
wire.
This
removes
any
loose
metal
chips
and dirt
that
may
have
accumulated.
a
CAUTION:
FLYING
DIRT AND
METAL PARTI
CLES
can
Injure
personnel
and
damage
equIpment.

PoTht
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
wire
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.
A
slight
twist
clockwise aids
re
moval
and
installation.
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.
CHANGING
WIRE
SIZES
AND
REPLACING
LINER
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.
IMPORTANT:
.030
and
.035
in.
(0.8
and 0.9
mm)
di
ameter
wires
use
the
same
monocoll liner
and
outlet
guide.
Changing
from .030
in.
(0.8
mm)
wire
to
.035
in.
(0.9
mm)
wire
or
vice
versa
requires
changing
the
con
tact
tube
only
(see
Section
5-2).
To
change
from
.030
in.
(0.8
mm)
wire
or
.035
in.
(0.9
mm)
wire
tO
.023
in
(0.6mm)
wire
or
vice
versa,
or
to
re
place
monocoil
liner,
proceed
as
follows:
1.
Remove
nozzle.
A
slight
twist
clockwise aids
re
moval
and
installation.
2.
Cut
off
any
portion
of
electrode wire
which
extends
beyond
end
of
contact
tube.
a
CAUTION:
LOOSE
WELDING
WiRE
can
cause
Injury.

Keep
a
firm
hold
on
the wire
during
installa
tion,
removal,
and
threading
operations.
Spooled
wire has
tendency
to
unravel
rapidly
when
loosened from
the
spool.
a
WARNING:
HIGH CONCENTRATION OF
SHIELDING
GAS
can
harm health
or
kill.

Shut
off
gas
supply
when
not
in
use.
SECTION
5-
MAINTENANCE
OM-1028
Page
4

3.
Manually
retract
wire
onto
wire
spool
(see
wire
feeder
Owners
Manual).
4.
Remove
contact
tube
and
contact
tube
adapter.
5. Disconnect
gun
assembly
from
wire
feeder,
if
appli
cable,
and
lay
it
out
flat
(no
coils
in
cable/conduit).
6.
Remove
outlet
guide.
7.
Pull
Out
monocoil liner
from
gun/feeder
connector
end of
gun
assembly.
4A
CAUTION:
FLYING
DIRT AND METAL PAR
TICLES
can
Injure
personnel
and
damage
equipment.

Point
gun
liner
only
in
a
safe direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
8.
Clean
gun
casing
or
liner with
compressed
air
while
liner
or
welding
wire
is removed.
9.
Insert
new
monocoil liner into
gun/feeder
end of
gun
assembly.
Be
sure
monocoil
covered
with
tub
ing
is
at
the
gun/feeder
connector.
10.
Insert newoutlet
guide
so
that
1/8
in.
(3mm)
of liner
sticks
out.
Tighten
outlet
guide.
a
CAUTION: OVERTIGHTENING
OUTLET
GUIDE
damages
liner.

Do
not
overtighten
outlet
guide.
11.
Cut
off
liner
so
that
3/8
in.
(9.5
mm)
of
liner sticks
out
of
the
head
tube.
12.
install
contact
tube
adapter.
13.
Reinstall
appropriate
contact
tube
and
nozzle.
14.
Reinstall
gun
to
wire drive
assembly.
15.
Thread
welding
wire
according
to
the
wire
feeder
Owners
Manual,
and
resume
operation.
OM-1028
Page
5

17
SECTION
6-
PARTS
LIST
Figure
6-1.
Exploded
View
Of GA-17C
Gun
TC-124
605-A
2
11
10
14
16
OM-1028
Page
6