OM-1027
110 727A
August 1994
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Air-Cooled Gun
GA-16C And GA-16C1
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SAFETY PRECAUTIONS FOR GMAW GUNS
GMAW WELDING can be hazardous.
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information found in the wire feeder
and welding power source Owner’s Manuals. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
ARC RAYS can burn eyes and skin.
1. Always wear dry insulating gloves.
2. Insulate yourself from work and ground.
3. Do not touch live electrode or electrical parts.
4. Repair or replace worn, damaged, or cracked
gun or cable insulation.
5. Turn off welding power source before changing
contact tip or gun parts.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin with spatter-resistant
clothing.
HOT SURFACES can burn skin.
1. Allow gun to cool before touching.
2. Do not touch hot metal.
6. Keep all covers and handle securely in place.
3. Protect hot metal from contact by others.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
FUMES AND GASES can be hazardous
to your health.
1. Check for noise level limits exceeding those
specified by OSHA.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING WIRE can cause puncture
wounds.
WELDING can cause fire or explosion.
1. Keep hands and body away from gun tip when
trigger is pressed.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
GovernmentPrinting Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understandingdoes not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
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SECTION 1 – SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
Safety Alert Symbol
Signal Word
1
2
2
WARNING means possible death
or serious injury can happen.
WARNING
CAUTION
3
4
CAUTION means possible minor
injury or equipment damage can
happen.
ELECTRIC SHOCK can kill.
MOVING PARTS can injure.
• Do not touch live electrical parts.
• Keep away from moving parts.
• Disconnect input power before
• Keep all panels and covers closed
3
Statement Of Hazard And Re-
sult
installing or servicing.
when operating.
4
Safety Instructions To Avoid
Hazard
5
5
6
Hazard Symbol (If Available)
Safety Banner
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
Read safety blocks for each sym-
bol shown.
6
7
7
NOTE
Turn Off switch when using high frequency.
Special instructions for best oper-
NOTE
ation – not related to safety.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Welding Gun
Specifications
Description
Rated Output
Duty Cycle
Wire Diameter
Weight
160 Amperes Using CO Shielding Gas – Air-Cooled
2
See Figure 2-1
.023 And .030 in (0.6 And 0.8 mm) Hard Or Flux-Cored Wires
10 ft Gun – Net: 2.8 lb (1.3 kg); Ship: 5.4 lb (2.4 kg)
2-1. Duty Cycle
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.
• Do not weld at rated load longer than shown below.
wfwarn8.1 8/93
0
Definition
10
Duty Cycle is percentage of 10
Minutes
minutes that gun can weld at
rated load without overheating.
60% Duty Cycle At 160 Amperes Using CO Gas
30% Duty Cycle At 160 Amperes Using Mixed Gases
2
6 Minutes Welding
4 Minutes Resting
3 Minutes Welding
7 Minutes Resting
sb1.5 8/93
Figure 2-1. Duty Cycle
OM-1027 Page 1
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SECTION 3 – INSTALLATION
3-1. Preparing And Installing Gun
GA-16C Model
1
2
3
Gun Securing Nut
Drive Assembly
Gun End
Loosen securing nut. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
3
4
Gun Trigger Plug Or
Terminals
Insert into receptacle and tighten
threaded collar, or connect to
matching terminals inside unit.
4
1
2
Close door.
See wire feeder manual for thread-
ing procedure.
GA-16C1 Model
3
Tools Needed:
5/16 in
4
1
2
Ref. ST-151 357 / Ref. ST-149 629-C / Ref. ST-155 506
Figure 3-1. Installing Gun
SECTION 4 – OPERATION
READ SAFETY BLOCKS at beginning
of manual before proceeding.
WARNING
4-1. Operating The Gun
1
Trigger Switch
When pressed, energized wire
feeds and shielding gas flows.
1
Ref. S-0621-C
Figure 4-1. Using Gun Switch
OM-1027 Page 2
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SECTION 5 – MAINTENANCE & TROUBLESHOOTING
READ SAFETY BLOCKS at beginning
of manual before proceeding.
WARNING
5-1. Maintenance And Troubleshooting
3 Months
Each Spool Of Wire
Turn Off all power before
maintaining.
Replace
Cracked
Parts
Blow Out
Gun
Casing
See
Section
5-2
– –
Control Cord
Gun Cable
Clean
Nozzle
And Check
Contact Tip
– –
Gas Hose
Figure 5-1. Routine Maintenance
Table 5-1. Troubleshooting
Trouble
Remedy
Wire does not feed.
Check contact tip. Check for kinks in gun cable. Check trigger connection at
welding power source/wire feeder. Have nearest Factory Authorized Service
Station/Service Distributor check gun trigger switch.
Wire is not energized.
Wire feeds unevenly.
Check contact tip. Check trigger connection at welding power source/wire feed-
er. Have nearest Factory Authorized Service Station/Service Distributor check
gun trigger switch.
Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.
5-2. Changing Contact Tip And Liner
Turn off welding power source/wire
feeder. Cut off wire at nozzle.
1
2
3
Nozzle
3
Contact Tip
2
Contact Tip Adapter
1
Tools Needed:
Ref. ST-149 326-A
Figure 5-2. Changing Contact Tip
OM-1027 Page 3
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CAUTION
FLYING METAL CHIPS AND DIRT can cause injury and damage equipment.
• Point gun away from people and in a safe direction when blowing out with compressed air.
Turn off welding power
source/wire feeder.
Head Tube
3/8 in
Remove nozzle,
contact tip, and
liner collet.
3/8 in
Remove liner.
To Reassemble Gun:
Install contact tip.
Insert new liner.
Gun/Feeder
Connector
Blow out
gun casing.
Install collet onto liner and tighten
into gun/feeder connector using
wrench.
Cut liner off near collet so that liner
end is as close to drive rolls as pos-
sible without touching.
Tools Needed:
Install nozzle.
3/8 in
Ref. ST-155 509
Figure 5-3. Changing Liner
OM-1027 Page 4
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SECTION 6 – PARTS LIST
Item
No.
Part
No.
Description
Quantity
Figure 6-1. Complete Assembly (GA-16C Gun Illustrated)
. . . 1 . . . . . . . . . . 110 793 . . HANDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 110 795 . . TUBE, head (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 110 780 . . . . NUT, M 10 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . 110 779 . . . . JACKET, head tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 110 781 . . . . STOP, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 128 878 . . . . ADAPTER, head tube nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 110 782 . . . . SPRING, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 110 785 . . TIP, contact .023 (16C Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 110 786 . . TIP, contact .030 (16C1 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 110 789 . . NOZZLE, slip type 1/2 orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . ♦112 420 . . NOZZLE, slip type 3/8 orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . ♦110 790 . . NOZZLE, spot flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . ♦110 791 . . NOZZLE, spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 110 794 . . TRIGGER SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 080 565 . . TERMINAL, frict uninsul fem 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . 110 792 . . CABLE, 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 110 797 . . SLEEVE, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 167 440 . . LINER, monocoil .023-.035 wire 10ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 110 784 . . . . COLLET, liner .023-.030 wire (16C Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 120 715 . . . . COLLET, liner .035 wire (16C1 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 079 974 . . O-RING, 1/2 ID x .103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . 110 796 . . CONNECTOR, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 079 878 . . CONNECTOR & PINS, (16C Model) (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . . . . . . . . . . 4
. . . 18 . . . . . . . . . . 047 994 . . TERMINAL, frict ultrafast fem 22-18ga (16C1 Model) . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . 048 834 . . CONNECTOR, circ clamp str rlf sz 11 Amp 206062-4 (16C Model) . . . . . . . . 1
9
. Hardware is common and
8
not available unless listed.
7
6
2
5
4
10
3
1
14
1
15
11
12
13
16
17
1
3
18
19
Ref. ST-110 832-D
Figure 6-1. Complete Assembly (GA-16C Gun Illustrated)
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1027 Page 5
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Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Support
3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
1. 5 Years Parts – 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
2. 3 Years — Parts and Labor
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
In the event of a warranty claim covered by this warranty, the
exclusive remedies 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 or credit for the purchase 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 F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
Grids
Maxstar 140
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Spot Welders
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
*
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
miller_warr 7/00
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
2000 Miller Electric Mfg. Co. 6/00
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