Miller JK48 Owner's manual

Miller
Brand
Miller
Model
JK48
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
August
1990
FORM:
OM-1541A
Effective
With
Style
No.
JK-48
MODEL:
GW-55C
GW-55P
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
aliow
untrained
persons
to
instaii,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fuiiy
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd..
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
lJ.S.A
u-I-
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
U
This
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
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Exceptas
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
thatcome
in
contactwith
thewelclingwire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
MILLERs
option
(1)
repair
or
(2)
replace-
mentor,
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
FOB.,
Factory
at
Appleton,
Wisconsin,
or
F.O.B.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
1.
UI
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3
INSTALLATION
Add
Section
3-5.
CORROSION
PREVENTION
Prevent
corrosion
in
the
torch
and
cooling
system
by
following
these
guidelines:
a.
Do
not
allow
aluminum,
steel,
cadmium
plate,
soft
(lead)
solder,
or
zinc
materials
to
contact
the
cooling
fluid.
Metal
materials
in
contact
with
the
cooling
fluid
must
be
made
of
brass,
copper,
silver
solder,
or
300
Series
stainless
steel.
b.
Use
only
good
quality
hoses
and
tubing
that
do
not
contain
carbon
or
steel
reinforcing.
c.
Use
only
brass,
plastic,
or
stainless
steel
fittings.
c.
Add
chlorine
bleach
to
the
coolant
system
to
eliminate
algae.
Add
1/2
oz.
(15
ml)
bleach
to
Radiator
and
Watermate
models
1A
and
2A.
Add
1
oz.
(30
ml)
bleach
to
Coolmate
4
models.
Using
more
than
the
specified
amount
of
bleach
in
the
coolant
system
will
increase
corrosion
and
shorten
the
life
of
the
system.
d.
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
antifreezes
that
contain
anti-leak
compounds
which
could
block
torch
cooling
passages.
e.
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.
f.
Make
sure
all
electrical
connections
are
tight.
Do
not
make
electrical
connections
with
connectors
made
of
different
metals.
AMENDMENT
TO
SECTION
6
PARTS
LIST
Amend
Parts
List
as
follows:
Part
Replaced
No.
With
Description
Quant~y
7-35
...
082
366
....
141
936
.
STRAIN
RELIEF,
cable
flexible
(Eff
w/KB1
9)
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following safety
alert
symbol
and
signal
words
are
Information
presented
in
this
manual
and
on
various
Ia-
usedthroughoutthismanualtocallattentiontoandiden
bets,
tags,
and
plates
on
the
unit
pertains
to
equipment
tify
different
levels
of
hazard
and
special
instructions.
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
This
safety
alert
symbol
is
used
with
the
signal
followed
forthe
safe
and
effective
use
of
this
equipment.
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble-
WARNING
statements
identify
procedures
or
shooting
of
arc
welding
equipment
requires
practices
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
toss
of
life.
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in-
CAUTION
statements
identify
procedures
or
stalled,
operated,
and
maintained
only
by
qualified
per-
practices
which
must
be
followed
to
avoid
minor
sons
in
accordance
with
this
manual
and
all
applicable
personal
injury
or
damage
to
this
equipment.
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of Arc
Weld-
IMPORTANT
statements
identify
special
instructions
ing
Power
Source
in
the
welding
power
source
Owners
necessary
for
the
most
efficient
operation
of
this
equip
Manual.
ment.
SECTION
2-
INTRODUCTION
Table
2-1.
SpecifIcations
Ampere
Ratina
100%
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
Ship
55OAWithCO2
500
A
With
Aroon
Or
Argon
MixedGas
Hard
Or
Flux
Cored
Wire
0.035
-
3/32
in.
0.9-2.4mm
Aluminum
Wire
0.035-1/16
in.
0.9
-
1.6
mm
10
ft.
(3.05
m)
15
ft.
(4.57
m)
Water
7-1/2
lbs.
(3.40
kg)
8-1/2
lbs.
(3.86
kg)
10
lbs.
(4.54
kg)
11
lbs.
(4.99
kg)
2-1.
DUTY
CYCLE
The
alpha-numeric
designation
refers
to
the
following:
The
duty
cycle
of
awelding
gun
is
the
percentage
of
aten
G
Gun
minute
penod
that
a
gun
can
be
operated
at
a
given
out
put
without
overheating
and
damaging
the
gun.
This
gun
W
Water
Cooled
is
rated
at
100%
duty
cycle
using
C02
shielding
gas
and
100%
duty
cycle
using
Argon
or
Argon
mixed
gas.
This
55
Ampere
Rating:
550
Amperes
means
the
gun
can
be
operated
continuously
at
550A
with
C02
shielding
gas
and
continuously
at
550A
with
C
Curved
Head
Tube
Argon
or
Argon
mixed
gas.
If
rated
amperage
is
ex-
.
ceeded,
the
duty
cycle
must
be
reduced.
P
Pistol
Grip
(Straight
Head
Tube)
a
CAUTION:
EXCEEDING
THE
RATED
DUTY
The
guns
are
ordered
for
a
specific
wire
size,
but
through
CYCLE
can
result
In
damage
to
the
gun.
minor
changes
in
parts
the
guns
may
be used
with
van-
Do
not
exceed
rated
duty
cycle.
ous
wire
sizes.
2-2.
DESCRIPTION
If
aluminum
wire
is
used,
the
guns
with
10
ft.
(3.05
m)
cables
are
recommended.
This
unit
is
a
water-cooled
semiautomatic
Gas
Metal
Arc
Welding
(GMAW)
gun.
This
gun
is
specifically
for
use
TheGW-55C
models
are
equippedwithatrigger
locklor
with
the
Gas
Metal-Arc
Welding
(GMAW)
process.
operator
comfort
during
tong
welds.
OM-1541
Page
1
3-4.
WATER
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.
Connect
the,
blue
water
inlet
hose
from
the
gun
cable
to
the
water
out
connector
at
the
wire
feederorcoolant
sys
tern.
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
water
flow,
one
quart
per
minute
minimum,
flows
through
the
gun
during
operation.
It
coolant
flow
is
insufficient
or
stops,
the
weld
power
cable
will
be
damaged.
SECTION
4
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL
ARC
WELDING
(GMAW)
a
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
part
in
contact
with
the
wire
while
welding.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
outputwhen
the
gun
switch
is
depressed.
Keep
all
covers
and
panels
in
place
while
op
erating.
Warranty
is
void
it
the
welding
power
source
is
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,
eai
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Keep
your
head
Out
of
the
fumes.
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
coolbe
fore
han
dling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
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).
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.
Turn
on
the
shielding
gas
supply.
Energize
the
welding
power
source
and
the
wire
feeder
(refer
to
the
respective
Owners
Manual).
IMPORTANT:
When
installing
new
equipment,
or
after
prolongedshutdown,
allow
shielding
gas
to
flowcontinu
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.
8.
9.
OM-1541
Page
3
11.
Close
drive
roll
housing,
and
adjust
tension
(see
ap
propnate
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
mmto
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
automaticallywhen
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.
SHUTflNG
DOWN
1.
Stop
welding.
2.
Turn
oft
welding
power
source
and
wire
feeder.
3.
Turn
off
the
shielding
gas
and
water
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.
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.
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
airwhen
changing
wire.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated.
AA
CAUTION:
FLYING
DIRT
AND
METAL
PARTI
CLES
can
Injure
personnel
and
damage
equipment.
Point
gun
finer
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
five
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.
3.
Remove
contact
tube,
and
replace
with
new
contact
tube.
4.
Reinstall
nozzle,
and
resume
operation.
5-3.
CHANGING
WIRE
SIZES
AND
REPLACING
LINER
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.
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.
OM-1541
Page
4
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.
S
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.
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.
t.
Reinstall
liner
and
wire
guide.
11.
Install
appropriate
size
contact
tube
for
new
wire.
12.
Reinstall
insulator
and
nozzle.
Table
5-1.
Wire
Size
Parts
Wire
Size
Conversions
0.9
mm
0.035
in.
0.035
in
1.1
mm
0.045
in.
0.045
in.
1.3
mm
0.052
in.
0.052
in.
1.6mm
0.062
in.
1/16
in.
2mm
0.078
in.
5/64
in.
2.4
mm
0.093
in.
3/32
in.
Wife
Type
~1LT
f
-~
I
~
J
~
Wire
Size
0.035
in.
0.045
in.
0.052
in.
1/16
in.
5/64
in.
3/32
in.
0.035
in.
contact
tube
0.045
in.
contacttube
0.052
in.
contact
tube
1/l6in.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
5
b~o
C.),
F~)
0
.1~3
013
01
C.)
Z~O)
0)3
3
o~0
C.),
01
-~
-
t)
0
013
01
C,)
bo
0)
C.)3
3
(3,,)
C.)
53
0
(71
p.
-u
CD
0)
8
9
10
11
12
13
14
2
9
10
11
12
13
14
53
C1)~
rn
-I
0
0)
-4~
C/)
I
C)
-~1
CD
C,)
N
ID
7
32
26
27
TD-083
207-C
Figure
6-1.
MAin
Assembly
Quantity
-
Model
-
GW-55C1
GW-55P
Item
No.
Part
No.
Description
Figure
6-1.
Main
Assembly
1
082348
SCREW
4
082 347
NUT
handle
4
2
082 343
HANDLE,
gun
1
2
082 397
HANDLE,
gun
(consisting
of)
1
3
131497
~NUT,M4x10handle
5
4
131
495
SWITCH,
trigger
1
5
131
496
SCREW,
handle
M4
x
10
panhead
5
6
082
345
SPRING,
trigger
1
7
082
346
TRIGGER
1
8
082
344
SWITCH,
micro
1
9
082
340
TUBE,
hd curved
5odeg
1
9
082 339
TUBE,
hd
straight
1
10
082
341
WASHER
1
1
11
082
375
ADAPTER,
tube
contact
1
1
11
082
376
ADAPTER,tube
contact
...
1
1
12
082
369
TUBE,
contact
scr
.035
wire
1
1
12
082 370
TUBE,
contact
scr
.045
wire
1
1
12
082
371
TUBE,
contact
scr
.052
wire
1
1
12
082 372
TUBE,
contact
scr
1/16
wire
1
1
12
082
373
TUBE,
contact
scr
5/64
wire
1
1
12
082
374
TUBE,
contact
scr
3/32
wire
1 1
13
082
342
INSULATOR,
nozzle
1
1
14
082
378
NOZZLE,
scr
5/8
orifice
1
1
14
082
377
NOZZLE,
scr
3/4
orifice
1
1
14
.082
379
NOZZLE,
scr
spot
1
1
15
079
878
HOUSING
PLUG
&
PINS,
(consisting
of)
1
1
079
535
TERMINAL,
male
4
4
16
048834
CLAMP,cable
1
1
17
082396
FITTING,quickdisconnect
2 2
18
082368
CLAMP,hose
4
4
19
082391
ADAPTER,block(consistingof)
1
1
20
083 390
SCREW,
set
skt
hd
M5
x
.8-5H
x
5
mm
...
1
1
21
082
392
ADAPTER,
plug
1
1
22
082
405
KIT,
al
.035
-
.045
wire
lOft
(consisting
of)
1
1
23
082
386
.
LINER,
teflon
1
1
24
082
388
COLLET,
No.
10
1
1
25
082
395
GUIDE,
inlet
wire
1
1
22
082
404
KIT,
al
1/16
wire
lOft
(consisting
of)
1
1
23
082
387
.
LINER,
teflon
1
1
24
082
389
COLLET,
No.
5
1
1
25
082 395
GUIDE,
inlet
wire
1
1
26
079
196
FITTING,
brs
barbed
F
3/l6tbg
x
1/4NPT
1
1
27
010
604
FITTING,
hose
brs
bushing
1/4NPTx
5/8-18RH
....
1
1
28
047
502
HOSE,
gas
(consisting
of)
1
1
29
056
581
.
FITTING,
hose
brs
barbed
nipple
3/l6tbg
1
1
30
010606
FITTING,
hose
brs
nut
5/8-18RH
1
1
056
108
.
FITTING,
hose
brs
ferrule
.425
ID
x
.718
Ig
1
1
31
604 550
HOSE,
No.
1
(order
by
ft)
itt
ift
32
079
633
FITTING,
hose
brs
barbed
nipple
3/1
6tbg
1
1
33
083 546
BUSHING,
brs
1
1
34
058174
O-RING,.250lDx.3750D
1
1
35
082
366
STRAIN
RELIEF,
cable
1
1
36
082
393
GUIDE,
inlet
wire
.035
-
.045,
.052
-
1/16
1
1
36
082
394
GUIDE,
inlet
wire
5/64
-
3/32
1
1
37
082
383
LINER,
monocoil
lOft
.035
-
.045
wire
1
1
37
082
380
LINER,
monocoil
15ft
.035
-
.045
wire
1
1
OM-1541
Page
7
Quantity
Part
Model
No.
Description
GW-55C1
GW-55P
37
082384
37
082381
37
082385
37
082382
38
082350
38
082351
39
083307
39
083
308
40
082356
40
082357
41
082368
1
1
42
082367
1
1
43
083306
1
1
44
082367
1
1
45
082368
1
1
46
082362
1
1
47
082358
1
1
47
082359
1
1
48
082352
1
1
48
082353
1
1
49
082360
1
1
49
082361
50
082349
51
082363
51
082364
52
082354
52
082355
082 365
53
082
390
Optional
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
No.
Figure
6-1.
Main
Assembly
(contd)
1
I
1
1
1
1
I
1
1
1
1
1
1
1
1
1
1
1
1
1
LINER,
monocoil
lOft
.052
-
1/16
wire
LINER,
monocoil
15ft
.052
-
1/16
wire
LINER,
monocoil
lOft
5/64
-
3/32
wire
LINER,
monocoil
l5tt
5/64
-
3/32
wire
CABLE,
gun
lOft
(consisting
of)
CABLE,
gun
l5ft
(consisting
of)
HOSE,
water
lOft
(consisting
of)
HOSE,
water
15ft
(consisting
of)
HOSE,waterloft
HOSE,
water
l5ft
CLAMP,
hose
FITTING,
brs
HOSE,
water
2ft
(consisting
of)
FITTING,
brs
CLAMP,
hose
HOSE,
water
-
out
HOSE,
gas
lOft
HOSE,
gas
l5ft
CONDUIT,
lOft
CONDUIT,15ft
~CABLE,pwr
lOft
CABLE,
pwr
l5ft
CLAMP,
cable
CASING,
cable
lOft
CASING,
cable
15ft
CORD,
trigger
lOft
CORD,
trigger
l5ft
TERMINAL,
friction
female
SHIELD,
heat
1
1
I
1
1
1
I
1
1
1
1
1
1
1
1
OM-1541
Page
8
OPTIONS
AND
ACCESSORIES
ALUMINUM
KITS
Recommended
when
running
alumi
num
wire.
For
use
with
10
ft.
(3.Om)
gun
only.
Consists
of:
Teflon
liner
with
collet
and
wire
guide.
Wire
size:
.035
(0.9
mm),
.045
(1.1
mm)&
.052
(1.3mm)
Stock
No.
082
405
Wire
size:
1/16
(1.6mm)
Stock
No.
082
404
HEAT
SHIELD
Stock
No.
082
390
DSS-8
Dual
Schedule
Switch
lOft.
(3m)
Stock
No.
079
691
l5ft.(4.6m)
StockNo.079
693
Fastens
to
gun
handle
and
is
used
in
place
of
the
standard
gun
trigger.
Selects
schedule
and
operates
the
con
tactor.
Note:
Adaptor
cord,
Stock
No.
046
943.
is
required
when
using
a
DSS-8
or
DSS-9
switch
with
an
RCMP-1
or
RCDW-1
control
and
S-52A
or
S-54A
wire
feeder.
DSS-9
Dual
Schedule
Switch
lOft.(3m)
StockNo.071
832
l5ft.(4.6m)
StockNo,071
833
Fastens
to
gun
handle.
Selects
sched
ule.
Gun
trigger
switch
operates
the
con
tacto
r.
2/88
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14

Miller JK48 Owner's manual

Miller
Brand
Miller
Model
JK48
Category
Welding System
Type
Owner's manual
This manual is also suitable for
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents