Miller | KB19 | Owner Manual | Miller GW-55P User manual

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