June
1981
FORM:
OM-1
541
OWN
ER๎S
MANUAL
tillER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
Effective
With
Style
No.
JB-25
MODEL
GW-55C
GW-55P
NWSA
CODE
NO. 4579
PRINTED
IN
U.S.A.
๎~๎
๎~๎~P
~
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(๎
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Miller๎s
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Miller๎s
option
(11
repair
or
121
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
(
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customer๎s
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
Except
as
specified
below,
Miller๎s
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
k~
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
3
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER๎
WARRANTIES
DO
NOT
EXTEND
Ct~
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
?
of
the
date
of
such
failure.
MILLER๎S
WARRANTIES
TO,
ANY
CONSUMER.
:?,,
J~
,~,
J~
~
J~
~
Sept.~
29,
1984
FORM:
OM-1541
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Effective
With
Style
No.
JE-35
Part
No.
Description
Quantity
047
502
HOSE,
gas
(consisting
of)
1
010
603
.
FITTING,
hose-brass
barbed
nipple
1/4
TBG
1
010 606
.
FITTING,
hose-brass
nut
5/8-18
RH
1
604
550
.
HOSE,
No.
1
(order
byft)
2ft
010
604
FITTING,
hose-brass
bushing
1/4
NPT
x
5/8-18
RH
1
079
196
FITTING,
brass-barbed
F
3/16
TBG
x
1/4
NPT
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
F~LE
COPY
RETURN
TO FOLDER
SECITON
1
-
INTRODUCTION
Ratings
100%
Duty
Cycle
Wire
Diameter
Capacity
Cable
And
Hose
Length
Cooling
Method
Weight
Net
Ship
550
A
With
C02
500
A
With
Argon
Or
Argon
Mixed
Gas
Hard
Or
Flux
Cored
Wire
0.035-3/32
in.
0.9-2.4
mm
Aluminum
Wire
0.035-1/16
in.
0.9-1.6mm
10
ft.
3.05
m
15
ft.
4.57
m
Water
7-1/2
lb.
3.40
kg
8-1/2
lb.
3.86
kg
10
lb.
4.54
kg
11
lb.
4.99
kg
Figure
1-1.
Specifications
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
IMPORTANT
A
third
signal
word,
________
highlights
instruc
tions
which
need
special
emphasis
to
obtain the
most
efficient
operation
of
this
equipment.
B.
Safety
G
-Gun
W
-
Water
Cooled
55
-
Ampere
Rating:
550
Amperes
C
-
Curved
Headtube
P
-
Pistol
Grip
(Straight
Head
Tube)
WARNING
____________
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
minor
personal
injury
or
damage
to
this
equipment.
The
guns
are
ordered
for
a
specific
wire
size
but
through
minor
changes
in
parts
the
guns
may
be
used
with
various
wire
sizes.
If
aluminum
wire
is
used,
the
guns
with
10
ft.
cables
are
recommended.
The
GW-55C
models
are
equipped
with
a
trigger
lock
for
operator
comfort
during
long
welds.
SECTION
2
-
INSTALLATION
WARNING
ELECTRIC
SHOCK
can
kill.
Shut
down
welding
power
source
and
wire
feeder
and
be
sure
they
cannot
be
accidentally
energized
before
making
gun
connections.
2-1.
SHIELDING
GAS
CONNECTIONS
(Figure
2-11
-
Disconnect
the
gas
hose
from
the
barbed
fitting
on
the
wire
drive
assembly
of
the
wire
feeder.
Connect
the
gas
hose
from
the
wire
feeder
to
the
barbed
fitting
on
the
gun
cable.
2-2.
GUN/WIRE
FEEDER
CONNECTIONS
(Figure
2-1)
-
Loosen
the
gun/feeder
connector
securing
knob
on
the
wire
drive
assembly
of
the
wire
feeder.
Insert
gun
into
wire
drive
assembly
and
tighten
securing
knob.
Information
presented
in
this
manual
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owner๎s
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
and
___________
which
identify
different
levels
of
hazard.
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
arOund
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
-
These
guns
are
specifically
for
use
with
the
Gas
Metal-Arc
Welding
(GMAW)
process.
The
alpha-numeric
designation
refers
to
the
following:
WARNING
CAUTION
OM-1541
Page
1
Nozzle
Two
quick
disconnect
connectors
are
supplied
with
the
gun.
Install
these
to
the
water
inlet
and
outlet
hoses.
These
connectors
have
5/8-18
left
hand
threads.
Connect
the
blue
water
inlet
hose
from
the
gun
cable
to
the
water
out
connector
at
the
wire
feeder
or
coolant
system.
Connect
the
red
water
out
hose
from
the
gun
cable
to
the
water
in
connector
of
the
coolant
system
or
route
hose
to
a
drain.
Ensure
a
sufficient
water
flow,
one
quart
per
minute
minimum,
through
the
gun
during
opera
tion.
If
coolant
flow
is
insufficient
or
stops,
the
weld
power
cable
will
be
damaged.
2-5.
CHANGING
WIRE
SIZE
(Figure
2-1)
-
Table
2-1
shows
parts
that
are
required
for
each
wire
size.
Some
parts
are
common
to
more
than
one
wire
size.
Check
Table
2-1
for
part
changes
when
changing
from
one
wire
size
to
another.
IMPORTANT
______________
The
standard
contact
tube
adapter
allows
3/16/n.
(4.76mm)
recess
of
the
contact
tube
in
the
nozzle.
This
is
normally
used
for
spray
transfer
Gas
Metal-Arc
Welding
(GMA
W).
An
optional
contact
tube
is
available
that
allows
the
contact
tube
to
be
flush
with
the
nozzle.
This
is
normally
used
for
short
circuiting
GMA
W.
A.
Changing
The
Contact
Tube
1.
Retract
wire
from
gun
and
blow
out
liner
with
low
pressure
compressed
air.
2.
Slide
nozzle
off.
3.
Change
contact
tube
for
new
wire
size.
4.
Replace
nozzle.
Adapter
Monocoil
Liner
Wire
Tube
Adapter
Water
Out
Hose
Shown
With
Optional
Heat
Shield
Wire
Guide
Water
In
Trigger
Control
Plug
Teflon
Liner
Hoae
IMPORTANT
Quick
Disconnect
Fitting
Figure
2-1.
Gun
Components
The
outlet
wire
guide
of
the
gun
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
TD-083 206
2-3.
GUN
TRIGGER
CONNECTIONS
(Figure
2-1)
-
Locate
TRIGGER
receptacle
on
wire
feeder;
in
sert
plug
from
gun
into
receptacle
and
secure.
2-4.
WATER
CONNECTIONS
(Figure
2-1)
IMPORTANT
This
gun
is
for
use
with
a
wire
feeder
equipped
with
a
water
control
kit
or
a
coolant
system
(such
as
Radiator
1).
If
necessary,
install
water
control
kit
on
wire
feeder
or
obtain
coolant
system.
CAUTION
gun.
LACK
OF
COOLANT
can
damage
Page
2
Table
2-1.
Wire
Size
Parts
Wire
Size
Conversions
0.9
mm
1.1
mm
1.3mm
1.6mm
2mm
2.4mm
0.035
in.
0.045
in.
0.052
in.
0.062
in.
0.078
in.
0.093
in.
0.035
in.
0.045
in.
0.052
in.
1/16
in.
5/64
in.
3/32
in.
*
E
~
C
Wire
Type
๎E
.2
<
-~
&_
co
I
*
E
~
C
~
D
๎
<
~D
๎~
co
I
I~
co
I
*
E
~
C
~
~
<
-~
~
(0
I
-~
l_
CO
I
~D
I.~
CO
I
Wire
Size
0.03
5
in.
0.045
in.
0.052
in.
1/16
in.
5/64
in.
3/32
in.
tube
X
tube
tube
tube
tube
tube
monocoil
liner
monocoil
liner
monocoil
liner
Teflon
liner
X
liner
wire
guide
wire
guide
wire
guide
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
.
X
X
X
x
X
X
*10
ft.
guns
only
B.
Changing
Liner
&
(If
Necessary)
Wire
Guide
1.
Retract
wire
from
gun
and
blow
out
liner
with
low
pressure
compressed
air.
2.
Slide
nozzle
off.
3.
Remove
insulator
and
contact
tube.
4.
Remove
wire
guide
and
liner.
5.
For
monocoil
liner:
a.
Insert
new
liner
and
replace
wire
guide
(changing
size
if
necessary).
b.
Cut
liner
off
flush
with
contact
tube
adapter.
c.
Remove
wire
guide
and
liner.
d.
Cut
an
additional
1/4
in.
(6.4
mm)
from
the
liner.
e.
Replace
liner
and
wire
guide.
6.
For
Teflon
liner:
a.
Thread
collet
onto
liner
until
3/4
in.
(19
mm)
of
the
liner
sticks
out
of
the
collet.
b.
Insert
new
liner
and
replace
wire
guide.
Liner
should
stick
out
of
the
guide
approximately
1/16
in.
(1.6
mm).
c.
Cut
liner
off
flush
with
contact
tube
adapter.
d.
Remove
wire
guide
and
liner.
e.
Cut
an
additional
1/4
in.
(6.4
mm)
from
the
liner.
f.
Replace
liner
and
wire
guide.
7.
Change
contact
tube
for
new
wire
size.
8.
Replace
insulator
and
nozzle.
OM-1
541
Page
3
PARTS
LIST
June
1981
FORM:
OM-1
541
Effective
With
Style
No.
JIB-25
MODEL
GW-55C
GW-55P
0
01
a
0)
cc
CD
1
34
5
13141516
9
51
36
-17
33
20
๎18
37
21
TD-083
207-A
Figure
A
-
Complete
Assembly
Quantity
Model
GW-55C
I
GW-55P
Wire
Size
Item
Part
.9mm-i
.2mm
1.3mm-i
.6mm
2.Omm-2.4mm
.9mm-i
.2mm
1.3mm-i
.6mm
2.Omm-2.4mrn
No. No.
Description
.035-045๎
.052-1/16๎
5/64-3/32๎
.035-045๎
.052-063๎
5/64-3/32๎
Figure
A
Complete
Assembly
1
082 348
SCREW
4
4
4
082
347
NUT,
handle
4
4
4
2
082343
HANDLE,
gun
1
1
1
2
082
397
HANDLE,
gun
1
1
1
3
082 345
SPRING,
trigger
1 1
1
4
082
346
TRIGGER
1
1
1
5
082 344
SWITCH,
micro
1
1
1
5
082 400
SWITCH,
micro
1
1
1
6
082
340
TUBE,
head
-
curved
50
deg
1 1
1
6
082 339
TUBE,
head
-
straight
1
1 1
7
082
341
WASHER
1
1
1
1
1
1
8
082
375
ADAPTER,
tube
-
contact
1
1
1
1 1 1
9
082
369
TUBE,
contact
-
screw
.035
wire
1
1
9
082
370
TUBE,
contact
-
screw
.045
wire
1
1
9
082
371
TUBE,
contact
-
screw
.052
wire
1
1
9
082
372
TUBE,
contact
-
screw
1/16
wire
1
1
9
082 373
TUBE,
contact
-
screw
5/64
wire
1
1
9
082
374
TUBE,
contact
-
screw
3/32
wire
1 1
10
082 342
INSULATOR,
nozzle
1
1
1
1 1
1
11
082
377
NOZZLE,
screw
3/4
orifice
1
1
1
1
1
1
12
083
439
SCREW,
machine
-
flat
hd
M3x0.5x16MM
1
1
1
13
083 438
WASHER,flatM3
2 2
2
14
082
401
NUT,
switch
4
4
4
15
082
399
SPRING,
trigger
1 1
1
16
082 398
TRIGGER
1 1
1
17
082 403
SCREW,
trigger
1
1
1
18
082
402
SCREW,
handle
5 5
5
19
079
878
HOUSING
PLUG
&
PINS
(con
sisting
of)
1
1
1 1
1
1
079 535
.
TERMINAL,
male
4
4
4 4 4
4
20
048
834
CLAMP,
cable
1
1
1
1
1
1
21
082 396
FITTING,
disconnect
-
quick
water
2
2 2
2
2
2
22
082 368
CLAMP,
hose
4
4
4
4
4
4
23
082
391
ADAPTER,
block
(consisting
of)
1
1
1
1
1
1
24
083 390
.
SCREW,
set
-
socket
hd
M5x0.8-5Hx5MM
1
1
1
1
1
1
25
082
392
ADAPTER,
plug
1
1
1
1
1
1
26
t082
405
KIT,
aluminum,
.035
&
3/64
wire
10
ft
(consisting
of)
1
1
26 t082
404
KIT,
aluminum,
1/16
wire
10
ft
(consisting
of)
1
1
27
082 386
.
LINER,
teflon
1
1
27
082
387
.
LINER,
teflon
1
1
28
082388
.COLLET,
No.
10
1
1
28
082 389
.
COLLET,
No.
5
1
1
OM-1541
Page2
Quantity
Model
Wire
Size
.9mm-i
.2mm
1.3mm-i
.6mm
2.Omm-2.4mm
.9mm-i
.2mm
1.3mm-i
.6mm
2.Omm-2.4mm
.035-045
.052-1/16
5/64-3/32
.035-045
.052.063๎
5/64-3/32๎
tOptional
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Part
No.
No.
Description
Figure
A
GW-55C
Complete
Assembly
(Cont๎d.)
GW-55P
1
1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
๎
29
082395
.GUIDE,
inlet-wire
30
079 633
FITTING,
hose
-
brass
barbed
nipple3/16TBG
31
083
546
BUSHING,
brass
32
079975
O-RING,3/16I.D
33
082
366
STRAIN
RELIEF,
cable
34
082
393
GUIDE,
inlet
-
wire
35
082394
GUIDE,
inlet-wire
35
082
383
LINER,
monocoil
lOft
35
082 380
LINER,
monocoil
15
ft
35
082384
LINER,
monocoillOft
35
082381
LINER,monocoill5ft
35
082
385
LINER,
monocoil
lOft
35
082382
LINER,
monocoil
l5ft
36
082
350
CABLE,
gun
10
ft
(consisting
of)
36
082
351
CABLE,
gun
15
ft
(consisting
of)
37
083
307
.
HOSE,
water
10
ft
(consisting
of)
37
083
308
.
HOSE,
water
15
ft
(consisting
of)
38
082356
.
.HOSE,waterl0ft
38
082
357
.
.
HOSE,
water
15
ft
39
082
368
. .
CLAMP,
hose
40
082
367
. .
FITTING,
brass
-
barbed
41
083
306
.
HOSE,
water
2
ft
(consisting
of)
42
082
367
.
.
FITTING,
brass
-
barbed
43
082
368
.
.
CLAMP,
hose
44
082
362
.
.
HOSE,
water
-
out
45
082 358
.
HOSE,
gas
lOft
45
082
359
.
HOSE,
gas
l5ft
46
082
352
.
CONDUIT,
lOft
46
082
353
.
CONDUIT,
l5ft
47
082360
.CABLE,powerl0ft
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
47
082
361
48
082
349
49
082
363
49
082
364
50
082
354
50
082
355
082
365
51
t082
390
8
082
376
11
082378
11
082379
25
082
405
25
082
404
CABLE,
powerl5ft
CLAMP,
cable
CASING,
cable
10
ft
CASING,
cable
15
ft
CORD,
trigger
10
ft
CORD,
trigger
l5ft
TERMINAL,
friction
-
female
SHIELD,
heat
Optional
Parts
ADAPTER,
tube
Contact
NOZZLE,
screw
5/8
orifice
NOZZLE,
screw
-
spot
KIT,
aluminum
10
ft
KIT,
aluminum
10
ft
Page
3
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
