Miller GA-4OGL Owner's Manual
Millerfi
July
1991
FORM:
OM-1515C
Effective
With
Serial
No.
Style
No.
JD-29
MODEL:
GA-4OGL
T~1~
~7~3
c~~
J~7~
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
Appleton,
WI
54912
USA
Tel.
414-734-9821
ST.091
915-A
PRINTED
IN
LISA.
.
I
I
L
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
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
Millerisfree
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
lifeofless
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
requiredtohonorwarranty
claimsonwarranted
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.
Loadbanks
Iyear
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
daims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
or
any
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
authorized
Miller
service
station
or
(4)
payment
oforcredit
for
the
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.
ata
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
willbeallowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPUED
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
IMPUED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLERISEXCLUDED
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
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.
~~1
/
.1
I
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
andonvarious
la
bels,
tags,
and
plates
on
the
unit
pertainstoequipment
design,
installation,
operation,
maintenance,
and
trou
bleshooting
which
should
be
read,
understood,
and
fol
lowed
for
the
safe
and
effective
use
of this
equipment.
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
the
front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
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
istobe
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
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
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
2INTRODUCTION
Table
2-1.
Specifications
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
out
put
without
overheating
and
damaging
the
gun.
This
gun
is
rated
at
60%
duty
cycle.
This
means
the
gun
can
be
operated
at
400
amperes
for six
minutes
out
often.
Dur
ing
the
remaining
four
minutes,
the
gun
must
operate
at
no
load
to
permit
proper
cooling.
If
rated
amperage
is
ex
ceeded,
the
duty
cycle
must
be
reduced.
2-2.
DESCRIPTION
This
gun
is
designed
specifically
for
use
with
the
self-
shielding
Flux
Cored
Arc
Welding
(FCAW)
process
us
ing
self-shielding
flux
cored
electrode.
The
gun
may
be
used
for
either
electrode
positive/dc
reverse
or
electrode
negative/dc
straight
polarity
applications.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered.
Through
minor
changes
in
parts,
the
gun
may
be
used
with
.045,
1/16,
.068/.072,
5/64,
or
3/32
in.
(1.2,
1.6,
1.8,
2.0,
or
2.4
mm)
flux
cored
wire.
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
A
Air
Cooled
40
Ampere
Rating:
400
Amperes
GL
Gasless
Ampere
Rating
60%
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
Ship
400
Amperes
.045
(1.2
mm)
1/16
in.
(1.6
mm)
.068/.072
in.
(1.7/1.8
mm)
5/64
in.
(2.0
mm)
3/32
in.
(2.4
mm)
lOft.
(3.0
m)
15ft
(4.6
m)
Air
8.5
lbs.
(3.9
kg)
10.5
lbs.
(4.8
kg)
10.5
lbs.
(4.8
kg)
12.5
lbs.
(5.7
kg)
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.
OM-1515
Page
1
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