Miller GA-5OGL Owner's Manual
Millerfi
August
1990
FORM:
OM-1532B
Effective
With
Style
No.
KA-27
MODEL::
GA-5OGL
OWNERS
MANUAL
4.
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
operationofwelding
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.
A
Miller
Group
Ltd.,
Company
a
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
B-045
t14
PRINTED
IN
U.S.A.
I
J
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
withnoother
guaTantees
or
warranties
expressed
or
implied.
IF
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
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
accessories
and
other
items
are
sold
subject
to
the
warrantiesoftheir
respective
manufacturers,
if
any.
All
engines
are
warrantiedbytheir
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
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,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
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.
Replacementorrepair
parts,
exclusiveoflabor
60
days
7.
Batteries
6
months
provided
that
MILLERisnotified
in
writing
within
thirty
(30)
days
of
the
dateofsuch
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
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1)
repairor(2)
replace
ment
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
optionofrepairorreplacement
will
be
F.O.B.,
Factory
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
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
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
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
F!TNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLERISEXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I
March
16,
1992
FORM:
OM-1532
I
ERRATA
SHEET
___________________
-
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to-data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
5
MAINTENANCE
Add
the
following
IMPORTANT
blockatthe
beginning
of
Section
5-3.
CHANGING
WIRE
SIZES
IMPORTANT:
Guns
shipped
for
use
with
1/16,
.0687.072,
or
5/64
in.
(1.6,
1.8,
or2.
0
mm)
wire
do
not
haveastub
lin~
r
in
the
head
tube.
When
changing
to
a
larger
wire
size,
a
stub
liner
must
be
inserted
into
the
head
tube.
Guns
shipped
for
use
with
3/32,
7/64,
or
1/8
in.
(2.4,
2.8,
or
3.2
mm)
wire
have
a
stub
liner
in
the
head
tube.
When
changing
to
a
smaller
wire
size,
the
stub
liner
is
removed
and
the
monocoll
liner
goes
through
the
head
tube.
AMENDMENT
TO
SECTION
8
PARTS
LIST
Amend
Parts
List
as
follows:
Part
Replaced
No.
With
Description
Quantity
7-
Added
....
008
931
.
LINER,
monocoil
3/32-1/8
wirex7.250
1
7-26
...
008
759
....
088
759
.
LINER,
monocoil
3/32-1/8
wire
x
l5ft
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-15329
8/90
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
forany
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.
mationislocatedonthe
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
DateofPurchase
_____________________
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
SPECIFICATIONS
2-1.
Duty
Cycle
1
2-2.
Description
1
SECTION
3INSTALLATION
3-1.
Gun/Feeder
Connector
Installation
3
3-2.
Nozzle
(Optional)
3
3-3.
Installation
Of
Trigger
Switch
(Optional)
3
SECTION
4SEQUENCE
OF
OPERATION
4-1.
Flux
Cored
And
Manual
Submerged
Arc
Welding
3
4-2.
Shutting
Down
4
SECTION
5
MAINTENANCE
5-1.
Inspection
And
Upkeep
4
5-2.
Contact
Tube
Replacement
4
5-3.
Changing
Wire
Sizes
5
SECTION
6
PARTS
LIST
Figure
6-1
Exploded
View
Of
Gun
(Gun
With
1/16
Wire
Illustrated)
6
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
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