Miller GW-55C User manual

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. [phone]
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

SECTION
3-INSTALLATION
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
elect
rica!
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
line
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
into
TRIGGER
receptacle
on
wire
feeder
as
follows:
align keyways,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
Contact
Tube
Adapter.
Shown
With
Optional
Heat Shield
Contact
Tube
Adapter
ilck
Disconnect
Fining
Input
Fitting
Out
Hose
Fitting
Figure
3-1.
Gun
Components
Wire Guide
10-083
206
OM-1541
Page
2

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
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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