Millerfi
May
1993
Effective
With
Form:
OM-1541B
Style
No.
KB19
OWNERS
MANUAL
t~V1LL~
''~
GW-55C
And
GW-55P
U
Read
and
follow
these
instructions
and
all
U
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Callyourdistributorifyoudonotunderstand
the
directions.
1~Ifl
U
U
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
1079,
Appleton,
WI
54912
Co.,
P.O.
Box
414-734-9821
cover
8/92
PRINTEO
IN
USA
tax
Within
the
werrenty
periods
listed
below,
MILLER
will
repeir
or
replece
any
wer
rented
pens
or
components
thet
feil
due
to
such
detects
in
meleriel
or
workmenship.
MILLER
must
be
notified
in
writing
within
thirty
(30j
days
of
such
defect
or
feilure,
et
which
time
MILLER
will
provide
instructions
on
the
werrenty
cleim
procedures
to
be
followed.
M1LLER
shell
honor
werrenry
cleime
on
warrenled
equipment
listed
below
In
the
event
of
such
e
feilure
within
the
werranty
time
periods.
All
warrenty
time
periods
alert
on
the
dete
thet
the
equipment
was
delivered
to
the
originel
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor.
t.
5
Veers
Parts
3
Veers
Labor
*
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
-
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
*
Robots
3.
2
Years
Parts
and
Labor
*
Engine
Driven
Welding
Generators
jNOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
*
Air
Compressors
4.
1
Year
Pens
and
Labor
*
Motor
Driven
Guns
*
Process
Controllers
*
Water
Coolant
Systems
HF
Units
*
Grids
*
Spot
Welders
*
Load
Banks
*
50*
Transformers
Running
Gear/Trailers
*
Field
Options
)NOTE:
Field
options
are
covered under
True
Blue~M
tor
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
is
greater.)
C
Months
Batteries
90
Days
Parts
and
Labor
*
MIG
Guns/TIG
Torches
Plasma
Cutting
Torches
MILLERS
True
BluerM
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles.
contactors
and
relays
or
parts
that
fail
due
to
normal
wear
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
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
COMMER
CIALIINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
Ii
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
eaclusive
remedies
shall
be.
at
MILLERS
option:
jtj
repair:
or
)2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
j3j
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station:
or
j4j
payment
of
or
credit
for
the
pur
chase
price
Iless
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
espense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
atAppleton.
Wisconsin.
or
F
0.0.
at
a
MILLER
authorized
ser
vice
facility
as
defermined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THEEXTENT
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
CONSEOUENTIAL
DAMAGES
IINCLUDING
LOSS OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT.
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
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.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
DR
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EGUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U
SA.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
esclusion
of
incidental.
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
eaclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights.
and
other
righta
may
be
available,
but
may
vary
from
state
to
state
In
Canada,
legislation
in
some
provincea
provides
for
certain
additional
warranties
or
remedes
other
than
as
ateted
herein,
and
to
the
eat
ent
that
they
may
not
be
waived,
the
limitahons
and
eaclusions
set
oul
above
may
not
apply
This
Limiled
Warranty
provides
specific
legal
rights.
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
MILLERS
TRUE
BLUETM
UMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
ICC
or
newer)
This
limited
warranty
supersedes
eli
previous
MILLER
warrenties
end
is
eectusive
with
no
other
guerantees
or
warrentien
espressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below.
MILLER
Electric
Remote
Controls
Mtg.
Co..
Appleton.
Wisconsin,
werrente
to
its
original
reteil
purcheser
thet
new
Accessory
Kits
MILLER
equipment
sold
after
the
effective
date
of
this
limited
werranty
is
tree
of
de-
Re
lacement
Perts
fects
in
material
end
workmanship
at
the
time
it
is
shipped
by
MILLER.
TIltS
WAR
RANT?
IS
EXPRESSLV
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
5.
a-i
I
.
.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
Fj)e
any
Claims
for
loss
or
damage
With
the
delivering
carrier.
Assistance
for
filing
or
settling
c)ajmS
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
5
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date
of
Purchase
miller
5/aaa
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
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
is
to
be
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
Arc
Welding
Safety
Precautions
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.
4~
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
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
2-
INTRODUCTION
Table
2-1.
Specifications
Ampere
Rating
100%
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
Ship
550
A
With
CO
2
500
A
With
Argon
Or
Argon
Mixed
Gas
Hard
Or
Flux
Cored
Wire
0.035-3/32in.
(0.9
-
2.4
mm)
Aluminum
Wire
0.035
-
1/16
in.
(0.9
-
1
.6
mm)
loft.
(3.05
m)
15
ft.
(4.57
m)
Water
7-1/2Ibs.
(3.40
kg)
8-1/2lbs.
(3.86
kg)
10
lbs.
(4.54
kg)
11
lbs.
(4.99
kg)
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
100%
duty
cycle
using
C02
shielding
gas
and
100%
duty
cycle
using
Argon
or
Argon
mixed
gas.
This
means
the
gun
can
be
operated
continuously
at
550A
with
C02
shielding
gas
and
continuously
at
500A
with
Argon
or
Argon
mixed
gas.
If
rated
amperage
is
ex
ceeded,
the
duty
cycle
must
be
reduced.
a
CAUTION:
EXCEEDING
THE
RATED
DUTY
CYCLE
can
result
in
damage
to
the
gun.
.
Do
not
exceed
rated
duty
cycle.
2-2.
DESCRIPTION
This
unit
is
a
water-cooled
semiautomatic
Gas
Metal
Arc
Welding
(GMAW)
gun.
This
gun
is
specifically
for
use
with
the
Gas
Metal-Arc
Welding
(GMAW)
process.
The
alpha-numeric
designation
refers
to
the
following:
G-Gun
W
Water
Cooled
55
Ampere
Rating:
550
Amperes
C
Curved
Head
Tube
P
Pistol
Grip
(Straight
Head
Tube)
The
guns
are
ordered
for
a
specific
wire
size,
butthrough
minor
changes
in
parts
the
guns
may
be
used
with
vari
ous
wire
sizes.
If
aluminum
wire
is
used,
the
guns
with
10
ft.
(3.05
m)
cables
are
recommended.
The
GW-55C
models
are
equipped
with
a
trigger
lock
for
operator
comfort
during
long
welds.
OM~i
541
Page
1
SECTION
3
INSTALLATION
Nozzle
Contact
~
S
Tube
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting
or
installing
gun.
Lockout/tagging
procedures
consist
of
removing
input
power
plug
from
receptacle,
padlocking
Tine
disconnect
switch
in
open
position,
remov
ing
fuses
from
fuse
box,
or
shutting
off
and
red-
tagging
circuit
breaker
or
other
disconnecting
device.
3-1.
SHIELDING
GAS
CONNECTIONS
(Figure
3-1)
1.
Disconnect
the
gas
hose
from
the
barbed
fitting
on
the
wire
drive
assembly
of
the
wire
feeder.
2.
Connect
the
gas
hose
from
the
wire
feeder
to
the
barbed
fitting
on
the
gun
cable.
3-2.
GUN/WIRE
FEEDER
CONNECTIONS
(Figure
3-1)
Install
the
gun/feeder
connector
into
the
drive
assembly
on
the
wire
feeder
as
follows:
IMPORTANT:
The
wire
outlet
guide
is
provided
as
part
of the
gun
assembly.
1
-
Loosen
the
gun/feeder
connector
securing
knob
on
the wire
drive
assembly.
IMPORTANT:
Wire
guides
should
be
positioned
as
close
as
possible
to
the
drive
rolls
without
touching
them.
This
gives
wire
maximum
column
strength.
2.
Insert
gun
into
wire
drive
assembly
until
gun/feeder
connector
stops
against
wire
drive
assembly.
3.
Tighten
gun/feeder
connector
securing
knob.
3-3.
GUN
SWITCH
CONNECTION
(Figure
3-1)
Connect
gun
trigger
switch
plug
into
TRIGGER
recepta
cle
on
wire
feeder
as
follows:
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
3-4.
COOLANT
CONNECTION
(Figure
3-1)
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.
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.
Insulator
Contact
Tube
Adapter
Contact
Tube
Monocoil
I
d
Nozzle
p
Wire
Guide
Insulator
Shown
With
Optional
Heat
Shield
Quick
Disconnect
Fitting
Collet
Quick
Gun
Trigger
Switch
Plug
Water
Out
Hose
Figure
3-1.
Gun
Components
S
ST-083
206-B
OM-1541
Page
2
Connect
the
blue
water
inlet
hose
from
the
gun
cable
to
the
water
out
connector
at
the
wire
feeder
or
coolant
sys
tem.
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.
a
WARNING:
LACK
OF
COOLANT
can
dam
age
gun.
Be
sure
a
sufficient
coolant
flow,
one
quart
per
minute
minimum,
flows
through
the
gun
during
operation.
If
coolant
flow
is
insufficient
or
stops,
the
weld
power
cable
will
be
damaged.
3-5.
CORROSION
PREVENTION
Prevent
corrosion
in
the
welding
gun
and
coolant
system
by
following
these
guidelines:
1.
Metal
materials
in
contact
with
the
cooling
fluid
must
be
made
of
brass,
copper,
silver
solder,
or
300
Se
ries
stainless
steel.
Do
not
allow
aluminum,
steel,
cadmium
plate,
soft
(lead)
solder
or
zinc
materials
to
contact
cooling
fluid.
2.
Use
only
good
quality
hoses
and
tubing
that
do
not
contain
carbon
or
steel
reinforcing.
3.
Use
only
brass,
plastic,
or
stainless
steel
fittings
4.
If
operating
the
coolant
system
at
temperatures
below
freezing,
use
a
solution
of
ethylene
glycol
(MILLER
Part
No.
128
705)
in
the
system.
Avoid
using
automotive-type
antifreeze
that
contain
anti-leak
compounds
which
could
block
gun
cooling
passages.
5.
Do
not
change
the
coolant
unless
it
becomes
discolored
or
contaminated.
Add
soft,
high
quality
tap
water,
deionized
water,
or
distilled
water
to
the
system
to
maintain
coolant
level.
6.
Make
sure
all
electrical
connections
are
tight.
Do
not
make
electrical
connections
with
connectors
made
of
different
metals.
SECTION
4-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL
ARc
WELDING
(GMAW)
AA
WARNING;
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.
Do
not
touch
live
electrical
parts.
Do
not
touch
welding
wire
or
any
metal
parts
in
contact
with
the
welding
wire
while
welding.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
gun
switch
is
closed.
Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ea,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
~
~St
~
r.~c~(J
yij&~i
,,~au
(JUt
1.11
(II~
IUIII~.~.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE-
can
cause
puncture
wounds.
Do
not
point
gun
toward
any
part
of the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Do
not
use
near
flammable
material.
Allow
work
and
equipment
to
cool
before
han
dling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
aflect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Arc
Welding
Safety
Precautions
in
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
1.
Be
sure
that
proper
electrical
connections
have
been
made
to
the
welding
power
source
and
the
wire
feeder.
2.
Be
sure
that
the
welding
wire
has
been
properly
threaded
and
that
correct
initial
tensions
have
been
set
on
the
drive
rolls
(refer
to
the
appropriate
Own
ers
Manual).
3.
Be
sure
that
the
proper
shielding
gas
is
connected
to
the
shielding
gas
valve.
4.
Place
the
wire
feed
control(s)
in
the
required
posi
tion
for
the
welding
setup.
5.
Place
the
controls
on
the
welding
power
source
in
the
required
position
for
the
welding
setup
(refer
to
welding
power
source
Owners
Manual).
OM-1541
Page
3
6.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
7.
Prepare
for
welding
as
follows,
connect
work
clamp
to
clean,
bare
metal
at
workpiece.
8.
Turn
on
the
shielding
gas
and
coolant
supplies.
9.
Energize
the
welding
power
source
and
the
wire
feeder
(refer
to
the
respective
Owners
Manual).
IMPORTANT:
When
installing
new
equipment,
or
after
prolonged
shutdown,
allow
shielding
gas
to
flow
continu
ously
for
at
least
one
minute
before
welding
to
purge
the
shielding
gas
line.
To
avoid
wasting
wire
while
purging,
open
the
drive
roll
housing.
10.
Press
Purge
button
on
the
wire
feeder
(if
applicable)
or
the
gun
switch
to
purge
the
gas
line.
11.
Close
drive
roll
housing,
and
adjust
tension
(see
ap
propriate
Owners
Manual).
12.
Press
the
gun
trigger,
and
run
the
welding
wire
out
beyond
the
end
of
the
gas
nozzle.
Cut
the
wire
off
so
it
extends
out
1/4
to
3/8
in.
(6.4
mm
to
9.5
mm)
from
end
of
nozzle.
13.
Set
the
Wire
Speed
control
slightly
higher
than
an
ticipated
wire
speed.
14.
Hold
the
end
of
the
gas
nozzle
approximately
1/2
in.
(12.7
mm)
from
the
workpiece.
15.
Press
the
gun
trigger.
Gas
starts
to
flow,
wire
starts
to
feed,
and
the
arc
will
be
established.
If
the
welding
wire
appears
to
slip,
adjust
drive
roll
tension
accord
ing
to
wire
feeder
Owners
Manual.
16.
After
the
controls
on
the
welding
power
source
and
the
wire
feeder
(if
applicable)
have
been
adjusted
for
normal
operation,
the
welding
power
source
(and
wire
feeder)
will
function
automatically
when
the
gun
trigger
is
pressed.
Releasing
the
gun
trigger
will
ex
tinguish
the
arc
and
cause
the
wire
feed
and
gas
flow
to
stop.
4-2.
SHUTTING
DOWN
1.
Stopwelding.
2.
Turn
off
welding
power
source
and
wire
feeder.
3.
Turn
off
the
shielding
gas
and
coolant
supplies
at
their
source.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
5-
MAINTENANCE
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts:
tighten,
repair
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
dirt
that
has
accumulated
around
nozzle
opening
and
inside
nozzle.
3.
Repair
or
replace
as
required
all
hose
and
cables;
give
particular
attention
to
frayed
and
cracked
insu
lation
and
areas
where
it
enters
equipment.
4.
Remove
grease
and
grime
from
components
and
moisture
from
electrical
parts
and
cables.
5.
Blow
out
casing
with
compressed
air
when
changing
wire.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
5-2.
CONTACT
TUBE
REPLACEMENT
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
1.
Remove
nozzle
and
insulator.
2.
Cut
off
any
portion
of
electrode
wire
which
extends
beyond
end
of
contact
tube.
I
CAUTION:
FLYING
DIRTAND
METAL
PARTI
a
WARNING:
ELECTRIC
SHOCK
can
kill;
CLES
can
injure
personnel
and
damage
WELDING
WIRE
can
cause
puncture
equipment.
wounds;
HOT
SURFACES
can
cause
severe
burns.
OM-1541
Page
4
3.
Remove
contact
tube,
and
replace
with
new
contact
tube.
4.
Reinstall
nozzle,
and
resume
operation.
5-3.
CHANGING
WIRE
SIZES
AND
REPLACING
LINER
WARNING:
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
wire
feeder
before
working
on
gun.
Disconnect
gun
from
wire
feeder
before
in
specting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Table
5-1
shows
parts
that
are
required
for
each
wire
size.
Some
parts
are
common
to
more
than
one
wire
size.
Check
Table
5-1
for
part
changes
when
changing
from
one
wire
size
to
another.
IMPORTANT:
The
standard
contact
tube
adapter
al
lows
3/16
in.
(4.76mm)
recess
of
the
contact
tube
in
the
nozzle.
This
is
normally
used
for
spray
transfer
Gas
Me
tal-Arc
Welding
(GMAW).
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.
1.
Remove
nozzle
and
insulator.
A
slight
twist
clock
wise
aids
removal
and
installation.
2.
Cut
off
any
portion
of
electrode
wire
which
extends
beyond
end
of
contact
tube.
a
CAUTION:
LOOSE
WELDING
WIRE
can
cause
injury.
Keep
a
firm
hold
on
the
wire
during
installa
tion,
removal,
and
threading
operations.
Spooled
wire
has
tendency
to
unravel
rapidly
when
loosened
from
the
spool.
3.
Manually
retract
wire
onto
wire
spool
(see
wire
feeder
Owners
Manual).
4.
Remove
contact
tube
and
contact
tube
adapter.
5.
Disconnect
gun
assembly
from
wire
feeder,
if
appli
cable,
and
lay
it
out
flat
(no
coils
in
cable/conduit).
6.
Remove
outlet
guide.
7.
Pull
out
monocoil
liner
from
gun/feeder
connector
end
of
gun
assembly.
a
CAUTION:
FLYING
DIRT
AND
METAL
PARTI
CLES
can
injure
personnel
and
damage
equipment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
11.
Install
appropriate
size
contact
tube
for
new
wire.
12.
Reinstall
insulator
and
nozzle.
a
8.
Clean
gun
casing
or
liner
with
compressed
air
while
liner
or
welding
wire
is
removed.
9.
For
monocoil
liner:
a.
Thread
collet
onto
liner
until
3/4
in.
(19
mm)
of
the
liner
sticks
out
of
the
collet.
b.
Install
new
liner
and
reinstall.wire
guide
(chang
ing
size
if
applicable).
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.
Reinstall
liner
and
wire
guide.
10.
For
Teflon
liner:
a.
Thread
collet
onto
liner
until
3/4
in.
(19
mm)
of
the
liner
sticks
out
of
the
collet.
b.
Install
new
liner
and
reinstall
wire
guide
(chang
ing
size
if
applicable).
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.
Reinstall
liner
and
wire
guide.
OM-1541
Page
5
Table
5.1.
Wire
Size
Parts
Wire
Size
Conversions
0.9mm
0.035
in.
0.035
in.
1.1mm
0.045
in.
0.045
in.
1.3mm
0.052
in.
0.052
in.
1
.6
mm
0.062
in.
1/16
in.
2mm
0.078
in.
5/64
in.
2.4
mm
0.093
in.
3/32
in.
.
WreT
e
I
yp
-~-
E
~
.~
E
-~
<
p
e
I
-;-
E
~
~
E
~
2
<
I
I
-;-
E
~
.~
E
.~
<
e
I
__
~
c~
I
.
c~
I
Wire
Size
ao3sir
0045
in
0.052
in.
1/1
6in.
5/64
in.
3/32
in.
0.035
in.
contact
tube
0.045
in.
contact
tube
0.052
in.
contact
tube
1/16
in.
contacttube
5/64
in.
contact
tube
3/32
in.
contact
tube
0.035
-
0.045
in.
monocoil
liner
0.052
-
1/16
in.
monocoil
liner
5/64
-
3/32
in.
monocoil
liner
0.035
-
0.045
in.
Teflon
liner
1/16
in.
Teflon
liner
0.035
-
1/16
in.
wire
guide
5/64
-
3/32
in.
wire
guide
0.035
-
1/16
in.
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
X
X
*
lOft,
guns
only
OM-1541
Page
6
SECTION
6
PARTS
LIST
OM-1541
Page
7
I-
Wire
Size
I
.9
-
1.2
mm
1.3
-
1.6
mm
2.0
-
2.4
mm
.035
-
.045
in.
.052
-
1/16
in.
5/64
-
3/32
in.
41
*lncludes
Items
16
Thru
18
~IncIudes
Item
22
~32
20
31
29~~
~
27
~
I
19
22
ST-083
207-E
Figure
6-1.
Complete
Assembly
26
10*
31
32
19
9
33
42
34
17
37
35
OM-1541
Page
8
Item
Part
No.
No.
Description
Figure
6-1.
Complete
Assembly
Quantity
Model
GW-55CI
GW-55P
..
1
047
502..
056
581
. .
010
606
. .
HOSE,
gas
(consisting
of)
.
.
FITTING,
hose
brs
barbed
nipple
3Il6tbg
. .
FITTING,
hose
brs
nut
5/8-18RH
1
1
1
1
1
1
2
3
4
056
108
. .
604 550
.
.
010 604
..
079
196
..
141
936..
. .
FITTING,
hose
brs
ferrule
.425
ID
x
.718
Ig
.
.
HOSE,
No.
1
(order
by
ft)
FITTING,
hose
brs
bushing
1/4NPT
x
5/8-18RH
....
FITTING,
brs
barbed
F
3/l6tbg
x1/4NPT
STRAIN
RELIEF,
cable
flexible
1
lft
.
.
..
1
1
1
1
lft
1
1
1
5
5
082 393
..
082 394
..
GUIDE,
inlet
wire
.035
-
.045,
.052
-
1/16
GUIDE,
inlet
wire
5/64
-
3/32
1
1
1
1
6
082 383
..
LINER,
monocoil
lOft
.035
-
.045
wire
1
1
6
082
380
..
LINER,
monocoil
l5ft
.035
-
.045
wire
1 1
6
082
384
..
LINER,
monocoil
lOft
.052
-
1/16
wire
1
1
6
082
381
..
LINER,
monocoil
15ft
.052
-
1/16
wire
1
1
6
082 385
..
LINER,
monocoil
1
Oft
5/64
-
3/32
wire
1 1
6
082 382
..
LINER,
monocoil
15ft
5/64
-
3/32
wire
1
1
7
8
082
392..
082
391
..
083390..
ADAPTER,
plug
ADAPTER,
block
(consisting
of)
..
SCREW,
setskthd
M5x.8-5Hx5mm
1
1
1
1
1
1
9
082
368..
CLAMP,
hose
4
4
.
.
.
.
.
.
.
10
. .
10
. .
11
..
11
..
12
.
.
12
. .
13
..
..
..
..
..
..
..
..
082 350
..
082
351
..
082358..
082359..
082 360
.
.
082361
.
.
082352..
CABLE,
gun
lOft
(consisting
of)
CABLE,
gun
l5ft
(consisting
of)
..
HOSE,gas
lOft
..
HOSE,gasl5ft
..
CABLE,
pwr
lOft
..
CABLE,
pwr
15ft
..
CONDUI1
lOft
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.
13
. .
..
082353
.
.
..
CONDUIT,
15ft
1
1
.
14
. .
..
082
349
. .
..
CLAMP,
cable
. . . .
I
1
.
15
. .
..
082 363
..
..
CASING,
cable
lOft
.
..
.
1 1
.
15
.
.
..
082 364
.
.
..
CASING,
cable
lSft
.
..
.
1 1
.
.
16
.
.
16
.
.
..
..
082 354
.
.
082 355
.
.
082
365
. .
..
CORD,
trigger
lOft
..
CORD,
trigger
15ft
.
.
TERMINAL,
friction
female
.
..
.
.
.
1
.
1
.
1
1
1
1
.
17
. .
..
083
306
.
.
082 367
HOSE,
water
2ft
(consisting
of)
.
FITTING,
brs
.
.
.
1
.
1
1
1
082 368
CLAMP,
hose
1 1
082 362
HOSE,
water
out
2ft
1
1
.
.
18
. .
18
. .
..
..
083 307
. .
083 308
.
.
082
356
..
HOSE,
water
lOft
(consisting
of)
..
HOSE,
water
15ft
(consisting
of)
HOSE,
water
lOft
1
1
1
1
1
1
082 357
HOSE,
water
l5ft
1
1
082
368
CLAMP,
hose
1
1
082 367
FITTING,
brs
1
1
.
.
.
.
19
. .
19
.
.
20
. .
21
. .
..
. .
..
..
082343..
082 397
.
.
131
495
.
.
131
497
. .
HANDLE,gun
HANDLE,
gun
(consisting
of)
..
SWITCH,
trigger
..
NUT,
M4
x
10
handle
1
1
1
5
.
.
22
.
.
23
. .
..
..
131
496
.
.
082 348
..
..
SCREW,
handle
M4
x
10
panhead
SCREW
4
5
082 347
..
NUT,
handle
4
.
.
24
.
.
25
. .
..
..
082 345
..
082
346..
SPRING,
trigger
TRIGGER
1
1
.
26
. .
..
082
344
..
SWITCH,
micro
1
.
.
27
.
.
27
. .
..
..
082
340
..
082
339
..
TUBE,
hd
curved
5Odeg
TUBE,
hd
straight
I
1
OM-1541
Page
9
OPTIONAL
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1541
Page
10
Item
No.
Part
No.
Description
Figure
6-1.
Main
Assembly
(Continued)
Quantity
Model
GW-55CI
GW-55P
.
28
..
.
.
082341
..
WASHER
1 1
.
29
.
..
.
082
375
..
ADAPTER,
tube
contact
1
1
.
29
...
082
376
..
ADAPTER,
tube
contact
1 1
.
30
...
.
082 369
..
TUBE,
contact
scr
.035
wire
1
1
.
30
...
.
082
370
..
TUBE,
contact
scr
.045
wire
1
1
.
30
...
.
082
371
..
TUBE,
contact
scr
.052 wire
1
1
.
30
...
.
082 372
..
TUBE,
contact
scr
1/16
wire
1
1
.
30
...
.
082
373
..
TUBE,
contact
scr
5/64
wire
1
1
.
30
...
.
082
374
..
TUBE,
contact
scr
3/32
wire
1
1
.
31
..
.
082
342
..
INSULATOR,
nozzle
1
1
.
32
.
..
.
062
378..
NOZZLE,
scr
5/8
orifice
1
1
.
32
...
082
377
..
NOZZLE,
scr
3/4
orifice
1
1
.
32
...
082
379..
NOZZLE,
scr
spot
1
1
.
33
...
082390..
SHIELD,heat
1
.
34
.
..
.
082
396..
FITTING,
quick
disconnect
2
2
.
35
. .
.
.
079 878
..
CONNECTOR
&
PINS,
(consisting
of)
1 1
079
535
.
. .
.
CONNECTOR,
circ
pin
push-in
14-l8ga
Amp
66359-6
4
4
.
36
. . .
.
048
834
..
CONNECTOR,
circ
clamp
str
rlfszll
Amp
206062-4
1
1
.
37
...
082
405
..
KIT,
al
.035
-
.045
wire
lOft
(consisting
of)
1
1
.
38
...
.
082
386
. .
..
LINER,
teflon
1
1
.
39
...
.
082 388
. .
..
COLLET,
No.
10
1
1
.
40
...
.
082 395
. .
..
GUIDE,
inlet
wire
1
1
.
37
.
..
082
404
. .
KIT,
al
1/16
wire
lOft
(consisting
of)
1
1
.
38
.
..
.
082
387
..
..
LINER,
teflon
1
1
.
39
...
.
082 389
..
..
COLLET,
No.
5
1
1
.
40
...
.
082
395
..
..
GUIDE,
inlet
wire
1
1
.
41
.
..
.
058
174
..
0-RING,
.250
ID
x
.375
OD
1
1
.
42
.
..
.
083
546..
BUSHING,
brs
1
1
.
43
.
.
.
.
079
633
..
FITTING,
hose
brs
barbed
nipple
3/l6tbg
1
1
OPTIONS
AND
ACCESSORIES
ALUMINUM
KITS
Recommended
when
running
aluminum
wire.
Consists
of
Teflon
liner
with
collet
and
wire
guide.
(#082
405)
.035,
.045,
and
.052
in.
(0.9,
1.1,
1.3
mm)
(#082
404)
1/16
in.
(1.6
mm)
HEAT
SHIELD
(#082
390)
DSS-8
DUAL
SCHEDULE
SWITCH
(#079691)
lOft.
(3m)
(#079
693)
15
ft.
(4.6
m)
Fastens
to
gun
handle.
Used
in
place
of
standard
gun
trigger.
Selects
schedule
and
operates
the
contactor.
Note:
Adapter
cord
(#046
943)
is
required
when
using
a
DSS-8
switch
with
an
RCMP-
I
or
RCDW-
I
control
and
S-52A
or
S-54A
wire
feeder.
DSS-9
DUAL
SCHEDULE
SWITCH
(#071
832)
lOft.
(3m)
(#071
833)
15
ft.
(4.6
m)
Fastens
to
gun
handle.
Selects
schedule.
Gun
trigger
switch
operates
the
contactor
Note:
Adapter
cord
(#046
943)
is
required
when
using
a
DSS-9
switch
with
an
RCMP-
1
or
RCDW-
I
control
and
S-52A
or
S-54A
wire
feeder.
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
Miller GW-55C Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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