Miller KB19 Owner's manual

Brand: Miller

Model: KB19

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Millerﬁ

May

1993

Effective

With

Form:

OM-1541B

Style

No.

KB19

OWNERS

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

MILLERS

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

manufacturers

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

MILLERS

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

customers

risk

and

espense.

MILLERS

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.

MILLERS

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

manufacturers

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

Owners

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

Owners

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

ers

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

Owners

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

Owners

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

Owners

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

Owners

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

Owners

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
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16

Miller KB19 Owner's manual

Brand: Miller

Model: KB19

Category: Welding System

Type: Owner's manual

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