Page 1
OM-1027 110 727A
August 1994
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Air-Cooled Gun
GA-16C And GA-16C1
Visit our website at
www.MillerWelds.com
Page 2
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.
Page 3
SAFETY PRECAUTIONS FOR GMAW GUNS
WARNING
GMAW WELDING can be hazardous.
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.
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.
6. Keep all covers and handle securely in place.
ARC RAYS can burn eyes and skin.
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.
3. Protect hot metal from contact by others.
NOISE can damage hearing; SOME
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
WELDING WIRE can cause puncture
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
wounds.
1. Keep hands and body away from gun tip when
trigger is pressed.
EMF INFORMATION
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.
Government Printing 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
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us t o draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
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
sr7 7/93
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SECTION 1 – SAFETY INFORMATION
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 2
5
6
7
2
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
NOTE
3
4
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
Turn Off switch when using high frequency.
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
mod1.1 2/93
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation – not related to safety.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Welding Gun
Specifications Description
Rated Output 160 Amperes Using CO2 Shielding Gas – Air-Cooled
Duty Cycle See Figure 2-1
Wire Diameter .023 And .030 in (0.6 And 0.8 mm) Hard Or Flux-Cored Wires
Weight 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.
0
10
Minutes
Definition
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
wfwarn8.1 8/93
60% Duty Cycle At 160 Amperes Using CO
6 Minutes Welding 4 Minutes Resting
2
Gas
Figure 2-1. Duty Cycle
30% Duty Cycle At 160 Amperes Using Mixed Gases
3 Minutes Welding 7 Minutes Resting
sb1.5 8/93
OM-1027 Page 1
Page 6
SECTION 3 – INSTALLATION
3-1. Preparing And Installing Gun
GA-16C Model
12
GA-16C1 Model
1 Gun Securing Nut
2 Drive Assembly
3 Gun End
3
4
3
Loosen securing nut. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
4 Gun Trigger Plug Or
Terminals
Insert into receptacle and tighten
threaded collar, or connect to
matching terminals inside unit.
Close door.
See wire feeder manual for thread-
ing procedure.
Tools Needed:
12
WARNING
4-1. Operating The Gun
5/16 in
4
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.
1 Trigger Switch
When pressed, energized wire
feeds and shielding gas flows.
OM-1027 Page 2
1
Ref. S-0621-C
Figure 4-1. Using Gun Switch
Page 7
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
WARNING
5-1. Maintenance And Troubleshooting
Turn Off all power before
maintaining.
Each Spool Of Wire
See
Section
5-2
– –
Figure 5-1. Routine Maintenance
Table 5-1. Troubleshooting
Blow Out
Gun
Casing
Clean
Nozzle
And Check
Contact Tip
READ SAFETY BLOCKS at beginning
of manual before proceeding.
3 Months
Replace
Cracked
– –
Parts
Control Cord
Gas Hose Gun Cable
Trouble Remedy
Wire does not feed. Check contact tip. Check for kinks in gun cable. Check trigger connection at
Wire is not energized. Check contact tip. Check trigger connection at welding power source/wire feed-
Wire feeds unevenly. Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.
welding power source/wire feeder. Have nearest Factory Authorized Service
Station/Service Distributor check gun trigger switch.
er. Have nearest Factory Authorized Service Station/Service Distributor check
gun trigger switch.
5-2. Changing Contact Tip And Liner
Turn off welding power source/wire
feeder. Cut off wire at nozzle.
3
2
1
1 Nozzle
2 Contact Tip
3 Contact Tip Adapter
Tools Needed:
Ref. ST-149 326-A
Figure 5-2. Changing Contact Tip
OM-1027 Page 3
Page 8
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
Gun/Feeder
Connector
Blow out
gun casing.
Tools Needed:
3/8 in
Remove liner.
To Reassemble Gun:
Install contact tip.
Insert new liner.
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 possible without touching.
Install nozzle.
Ref. ST-155 509
OM-1027 Page 4
Figure 5-3. Changing Liner
Page 9
SECTION 6 – PARTS LIST
Item
No. Quantity
Part
No.
Description
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
8
7
2
6
5
. Hardware is common and
not available unless listed.
4
3
1
11
1
12
10
1
13
14
19
15
16
17
3
18
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
Page 10
Notes
Page 11
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Y our distributor also gives
you ...
Service
Y ou always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
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.
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
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.
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.
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.
1. 5 Years Parts – 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* 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)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* 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.)
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets
guarantees or warranties expressed or implied.
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 & Spoolmate 250
* Canvas Covers
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.
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.
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.
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.
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 bas e d u p o n a c tual 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.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. I N N O 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.
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
PROVISION, MIGHT ARISE BY IMPLICATION,
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.
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.
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.
miller_warr 7/00
Page 12
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
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
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
Miller Electric Mfg. Co.
An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-A t t ended
USA & Canada FAX: 9 20-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier for:
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
File a claim for loss or damage during
shipment.
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