GW-500 And GW-600
Processes
Description
MIG (GMAW) Welding
OM-1034 160 519
July 1994
Water-Cooled Gun
Visit our website at
www.MillerWelds.com
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.
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
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.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
sr7 7/93
SAFETY PRECAUTIONS FOR GMAW GUNS
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.
GMAW WELDING can be hazardous.
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.
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.
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.
NOISE can damage hearing; SOME
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.
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.
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.
WELDING WIRE can cause puncture
wounds.
1. Keep hands and body away from gun tip when
trigger is pressed.
EMF INFORMATION
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 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.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
OM-1034 Page 1
SECTION 1 – SAFETY INFORMATION
mod1.1 2/93OM-1034 – 7/94
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
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.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
3
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Specifications
Specifications Description
Rated Output AT 100% Duty Cycle GW-500: 500 Amperes Using CO
2
Shielding Gas; 450 Amperes Using Mixed Gas
GW-600: 650 Amperes Using CO
2
Shielding Gas; 600 Amperes Using Mixed Gas
Cooling Method Water
Wire Diameter .030 Thru 3/32 in (0.8 Thru 2.4 mm) Hard Or Flux Cored Wire
.030 Thru 1/16 in (0.8 Thru 1.6 mm) Aluminum Or Nickel Alloy Wires
Cable Length 10 ft (3 m) Or 15 ft (4.5 m)
Weight 10 ft Gun: Net: 9 lb (4.1 kg) Ship: 11 lb (5 kg) Or 15 ft Gun: Net: 10 lb (4.5 kg) Ship: 12 lb (5.4 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
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
sb1.5* 8/93
0
10
Minutes
100% Duty Cycle At 500 Amperes Using CO
2
Gas
Definition
Continuous Welding
100% Duty Cycle At 450 Amperes Using Mixed Gas
100% Duty Cycle At 600 Amperes Using Mixed Gas
100% Duty Cycle At 650 Amperes Using CO
2
Gas
Figure 2-1. Duty Cycle
OM-1034 Page 2
SECTION 3 – INSTALLING THE GUN
3-1. Installing The Gun
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off wire feeder and welding power source, and
disconnect input power before inspecting,
maintaining, or servicing.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.
swarn8.2* 10/91
1 Gun Securing Knob
2 Drive Assembly
3 Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
knob.
4 Gun Trigger Plug
Insert into receptacle, and tighten
threaded collar.
Close drive assembly cover.
5 Water Inlet Hose
6 Water Outlet Hose
Connect hoses to supplied quick
disconnect fittings. Make connec-
tions to coolant supply. Water flow
is controlled by the coolant supply.
ST-160 992
1
2 3
4
5 6
Figure 3-1. Gun And Trigger Connections
1 Drive Assembly Gas Fitting
2 Gun Gas Fitting
3 Gas Hose From Wire Feeder
To use existing gas connections at
wire feeder, remove gas hose from
fitting on drive assembly and push
onto barbed fitting on gun.
Ref. ST-160 994
1
2
3
Figure 3-2. Shielding Gas Connections
OM-1034 Page 3
3-2. Typical System Connections
ST-161 243
1
2
3
4
5
6
7
8
9
11
12
13
14
10
1 Welding Power Source
2 Positive Weld Output Cable
3 Remote 14 Cord
4 Remote 17 Cord
5 Negative Weld Output
Cable
6 Workpiece
7 Voltage Sensing Clamp
8 Welding Gun
9 Water Hoses
10 Wire Feeder
11 Coolant System
12 Coolant System Power
Cord
13 Gas Hose
14 Gas Cylinder
Figure 3-3. Typical System Connections
OM-1034 Page 4
3-3. Coolant Guidelines
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury.
• Do not touch live electrical parts.
• Keep away from moving parts.
• Disconnect input power plug from receptacle before
cleaning system components.
FAILURE TO PROPERLY MAINTAIN
COOLANT SYSTEM can cause damage
to the gun and coolant system.
• Circulate and flush clear water through entire
system, and replace coolant every six months.
INCORRECT COOLANT will damage
gun and coolant system.
• Use plain distilled or deionized water, or use high
quality tap water.
• In freezing temperatures use only a mix of pure
ethylene glycol and distilled or deionized water such
as MILLER coolant Part No. 128 705 or equivalent.
DO NOT USE AUTOMOTIVE ANTIFREEZE.
WARNING
Ref. S-0760
Follow these guidelines to
decrease corrosion in gun and
coolant system.
Material in contact with coolant can
only be brass, copper, silver solder,
300 Series stainless steel, or
plastic.
1 Coolant
See table for coolant mixture need-
ed for operating temperature.
2 Coolant System Tank
Keep coolant level full. Length of
coolant hoses affects amount of
coolant needed in unit.
Change coolant when dirty or every
6 months.
3 Connections
Keep connections tight. Make elec-
trical connections with connectors
of the same metal.
Tighten Connections
3
1
Coolant
TEMP.
Above 32° F
(0° C)
0° F (–18° C) to
32° F (0°C)
Below 0° F
(–18° C)
Distilled Or
High Quality
Tap Water
35% Ethylene
Glycol And 65%
Water
See Ethylene
Glycol
Manufacturer’s
Suggestion
FULL
Draining
2
Distilled Water
Filling
And Antifreeze
Figure 3-4. Coolant Guidelines
OM-1034 Page 5
SECTION 4 – OPERATING THE GUN
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrical parts.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
• Do not weld near flammable material.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not weld on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with correct shade of filter.
• Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
• Keep away from pinch points such as drive rolls.
• Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
• Pacemaker wearers keep away.
• Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Rules at beginning of wire feeder or welding
power source Owner’s Manual for basic welding safety
information.
swarn6.2* 10/91
The standard contact tip adapter allows 3/16 in (4.7 mm) recess of the contact tip
in the nozzle. This is normally used for spray transfer Gas Metal Arc Welding
(GMAW). An optional contact tip adapter is available for the GW-500 model that
allows the contact tip to be flush with the nozzle. This is normally used for short
circuiting GMAW. See Section 5-3 for contact tip adapter replacement procedure.
NOTE
1 Gun Trigger
When pressed, wire feeds and is
energized, and gas flows.
Trigger can be used as dual sched-
ule switch to change between pro-
grams. Press lightly for schedule A
and press all the way down for
schedule B.
2 Trigger Rib
The trigger can be shortened by
breaking off along rib.
ST-160 991
1
2
Figure 4-1. Gun Switch
OM-1034 Page 6
SECTION 5 – MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off wire feeder and welding power source, and
disconnect input power before inspecting,
maintaining, or servicing.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.
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.
Maintenance to be performed only by qualified persons.
swarn8.2* 10/91
5-1. Routine Maintenance
Turn Off all power before
maintaining.
3 Months
Replace
Unreadable
Labels
3 Months
See
Section
6
Tape Or
Replace
Cracked
Weld
Cable
– –
Control Cord
Gas Hose Gun Cable
– –
Replace
Cracked
Parts
Blow Out
Gun
Casing
Each Spool Of Wire
Clean
Drive
Rolls
– –
– –
Figure 5-1. Routine Maintenance
5-2. Replacing Gun Contact Tip
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Turn Off wire feeder and welding
power source.
1 Nozzle
Cut off welding wire at contact tip.
Remove nozzle
2 Contact Tip
Remove contact tip and install new
contact tip. Reinstall nozzle.
ST-160 995
1
2
Tools Needed:
Figure 5-2. Replacing Contact Tube
OM-1034 Page 7
Table 5-1. Wire Size Parts
Contact Tips
Inches Millimeters
Steel Liner Steel Liner Wire Guide Alum/Nickel Liner
.030 0.8 .030/.035 .030-5/64 .030/.035
.035 0.9 .030/.035 .030-5/64 .030/.035
.045 1.1 .045/.052 .030-5/64 .045-1/16
.052 1.3 .045/.052 .030-5/64 .045-1/16
1/16 1.6 1/16 / 5/64 .030-5/64 .045-1/16
5/64 2.0 1/16 / 5/64 .030-5/64 – –
3/32 2.4 3/32 3/32 – –
5-3. Cleaning Or Replacing Gun Liner
READ SAFETY BLOCKS at start of Section 5 before proceeding.
WARNING
Carbon teflon liners are for use with aluminum and nickel alloy wire.
NOTE
Turn Off wire feeder and welding
power source and disconnect input
power.
Cut welding wire off at contact tip.
Retract wire onto spool and secure.
1 Gun Securing Knob
Disconnect shielding gas hose,
trigger plug, and water hoses.
Loosen knob and remove gun.
2 Nozzle
3 Contact Tip
4 Contact Tip Adapter
5 Insulator
6 Head Tube
7 Monocoil Liner With Collet
8 Wire Outlet Guide
Disassemble gun as shown.
Pull liner from outlet guide end.
Blow gun casing out with com-
pressed air.
9 Collet
10 Teflon Liner
Twist collet onto teflon liner until 3/4
in (19 mm) of the liner sticks out.
Insert new liner into gun casing. In-
stall wire outlet guide. Liner should
stick out of guide 1/16 in (1.6 mm).
Cut liner off flush with head tube
where contact tip adapter threads
on.
Remove wire guide and liner. Cut
1/4 in (6 mm) more off liner end that
goes to contact tip adapter. Rein-
stall liner into gun casing.
Reassemble gun. Reinstall gun.
Thread welding wire according to
wire feeder Owner’s Manual.
ST-160 992 / ST-160 996
Tools Needed:
3/8 in
1
2
3
4
5
6
7
8
9
10
Figure 5-3. Replacing Gun Liner
OM-1034 Page 8
SECTION 6 – PARTS LIST
1
2
3
4
5
6*
7
8
9
10
11
12
13
14
31
32
33
15
17
16
18
19
20
21
22
23
30
24
25
26
27
28
35
37
38
39
40
41
36
29
17
16
16
18
20
21
22
23
Wire Size
.8-.9 mm
.030-.035 in
1.1-1.3 mm
.045-.052 in
1.6-2.0 mm
1/16-5/64 in
24
25
26
24
16
27
500 Model Gun End
600 Model Gun End
ST-160 990
Figure 6-1. Complete Assembly (500 & 600 Model)
*Includes Items 14 & 15
2.4 mm
3/32
29
34
. Hardware is common and
not available unless listed.
OM-1034 Page 9
GW-500Description
Part
No.
Item
No.
Figure 6-1. Complete Assembly
Quantity
Model
GW-600
1 047 502 HOSE, gas (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
056 851 FITTING, hose brs barbed nipple 3/16tbg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
056 108 FITTING, hose brs ferrule .425 ID x .718 lg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 606 FITTING, hose brs nut .625-18RH 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 834 HOSE, SAE .187 ID x .410 OD (order by ft) 1ft 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 010 604 FITTING, hose brs bushing 1/4NPT x .625-18RH 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 079 196 FITTING, brs barbed fem 3/16tbg x 1/4NPT 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 161 550 GUIDE, inlet steel liner .030-.052 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 161 551 GUIDE, inlet steel liner 1/16-3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 161 540 LINER, stl 17ft .030-.035 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 161 541 LINER, stl 17ft .045-.052 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 161 542 LINER, stl 17ft 1/16-5/64 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 161 543 LINER, stl 17ft 3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 161 531 CABLE ASSEMBLY, 10ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 161 511 CABLE ASSEMBLY, 10ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 161 532 CABLE ASSEMBLY, 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 161 512 CABLE ASSEMBLY, 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 082 368 CLAMP, hose 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 082 358 HOSE, gas 10ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 082 359 HOSE, gas 15ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 082 352 CONDUIT, 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 161 515 CONDUIT, 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 082 353 CONDUIT, 15ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 161 516 CONDUIT, 15ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 082 360 CABLE, pwr 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 161 513 CABLE, pwr 10ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 082 361 CABLE, pwr 15ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 161 514 CABLE, pwr 15ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 161 535 COVER, cable outer 10ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 161 536 COVER, cable outer 15ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 082 349 CLAMP, cable 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 161 517 SLEEVE, cable support 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 083 307 HOSE, water 10ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 083 308 HOSE, water 15ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 356 HOSE, water 10ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 357 HOSE, water 15ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 368 CLAMP, hose 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 367 FITTING, brs 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 161 533 WIRE, trigger 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 365 TERMINAL, friction female 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161 534 INSULATOR, connector 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 161 526 HANDLE, gun 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 161 503 HANDLE, gun 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 082 348 SCREW 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 161 506 SCREW, slotted head M4 x 10 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 161 507 SCREW, slotted head M4 x 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 347 NUT, handle 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 082 340 TUBE, head curved 50deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 161 502 HEAD TUBE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 082 341 WASHER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 082 375 ADAPTER, tube contact recess 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 161 519 ADAPTER, contact tube recess 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 ♦082 376 ADAPTER, tube contact flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 161 552 CONTACT TIP, .030 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 553 CONTACT TIP, .030 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 369 TUBE, cont scr .035 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 554 CONTACT TIP, .035 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 370 TUBE, cont scr .045 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 555 CONTACT TIP, .045 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 371 TUBE, cont scr .052 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1034 Page 10
GW-500Description
Part
No.
Item
No.
Figure 6-1. Complete Assembly (Continued)
Quantity
Model
GW-600
21 ♦161 556 CONTACT TIP, .052 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 372 TUBE, cont scr 1/16 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 557 CONTACT TIP, .062 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 373 TUBE, cont scr 5/64 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 558 CONTACT TIP, .078 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 082 374 TUBE, cont scr 3/32 wire x 30mm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦161 559 CONTACT TIP, .094 chrome zirconium 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 082 342 INSULATOR, nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 161 518 INSULATOR, nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦161 545 NOZZLE, conical .38 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦161 544 NOZZLE, conical .55 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 082 378 NOZZLE, scr .625 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦161 522 NOZZLE, conical .61 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦082 377 NOZZLE, scr .750 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 161 520 NOZZLE, conical .71 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦082 379 NOZZLE, scr spot .750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦161 521 NOZZLE, cylindrical .87 orifice 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 ♦161 523 NOZZLE, spot weld .87 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 161 530 KIT, trigger repair 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 161 510 KIT, trigger repair 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 161 529 SCREW, handle M4 x 10 panhead 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 161 505 SCREW, switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 161 528 SWITCH ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 161 509 SWITCH ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 161 527 TRIGGER, extended 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 161 508 TRIGGER, extended 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 161 504 PIN, roll 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 141 936 STRAIN RELIEF, cable flexible 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161 538 SCREW, slotted head M4 x 6 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 082 396 FITTING, quick disconnect 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 083 306 HOSE, water 2ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 362 HOSE, water out 2ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 368 CLAMP, hose 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
082 367 FITTING, brs 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 079 878 CONNECTOR & PINS, (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 535 CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 048 834 CONNECTOR, circ clamp str rlf sz 11 Amp 206062-4 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 161 539 ADAPTER ASSEMBLY 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 ♦159 722 KIT, aluminum & nickel alloy .030/.035 10ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
36 161 546 LINER, carbon teflon .030-.035 (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 082 388 COLLET, No. 10 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 082 395 GUIDE, wire inlet .035-3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 ♦161 336 KIT, aluminum & nickel alloy .030/.035 15ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
36 161 548 LINER, carbon teflon .030-.035 (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 082 388 COLLET, No. 10 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 082 395 GUIDE, wire inlet .035-3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 ♦159 723 KIT, aluminum & nickel alloy .045/.062 10ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
36 161 547 LINER, carbon teflon .045-.062 (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 082 388 COLLET, No. 10 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 082 395 GUIDE, wire inlet .035-3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 ♦161 337 KIT, aluminum & nickel alloy .045/.062 15ft (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
36 161 549 LINER, carbon teflon .045-.062 (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 082 388 COLLET, No. 10 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 082 395 GUIDE, wire inlet .035-3/32 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 058 174 O-RING, .250 ID x .375 OD 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 083 546 BUSHING, brs .500 OD x .257 ID x .187 lg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 079 633 FITTING, hose brs barbed nipple 3/16tbg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦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.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
miller_warr 7/00
Your distributor also gives
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hands in 24 hours.
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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
guarantees or warranties expressed or implied.
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
* 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 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.
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.
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.
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Always provide Model Name and Serial/Style Number.
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
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
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
For Service
Owner’s Record
File a claim for loss or damage during
shipment.
Contact your Distributor for:
/