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OM-248663J
Processes
MIG (GMAW) Welding
2017−09
Description
Semi-Automatic, Air/Water-
Cooled, MIG (GMAW) Welding
Gun
XR - Pistol - Plus
(Air And Water-Cooled Guns)
For product information,
Owner’s Manual translations, and more, visit
www.MillerWelds.com
File: MIG (GMAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance.
And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem.
Warranty and service information for your particular model are also provided.
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System
Standard.
Working as hard as you do
− every power source from
Miller is backed by the most hassle-free warranty in the business.
Miller Electric manufactures a full line of welders and welding related equipment.
For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
Mil_Thank 2017−06
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . . . .
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
Gun Drive Assembly Maintenance
Additional Safety Symbols And Definitions
Miscellaneous Symbols And Definitions
SECTION 8 − ELECTRICAL DIAGRAMS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES
WARRANTY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2015-09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1.
Symbol Usage
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
.
Indicates special instructions.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2.
Arc Welding Hazards
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.
BUILDUP OF GAS can injure or kill.
D
Shut off compressed gas supply when not in use.
D
Always ventilate confined spaces or use approved air-supplied respirator.
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the welding power source Owner’s Manual. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D
Always wear dry insulating gloves.
D
Insulate yourself from work and ground.
D
Do not touch live electrode or electrical parts.
D
Replace worn, damaged, or cracked guns or cables.
D
Turn off welding power source before changing contact tip or gun parts.
D
Keep all covers and handle securely in place.
FUMES AND GASES can be hazardous.
D
Keep your head out of the fumes.
D
Ventilate area, or use breathing device. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
D
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
WELDING can cause fire or explosion.
D
Do not weld near flammable material.
D
Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
D
Watch for fire; keep extinguisher nearby.
D
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
MOVING PARTS can injure.
D
Keep away from moving parts.
D
Keep away from pinch points such as drive rolls.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
D
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
D
Wear approved safety glasses with side shields under your helmet.
D
Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
D
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
HOT PARTS can burn.
D
Allow gun to cool before touching.
D
Do not touch hot metal.
D
Protect hot metal from contact by others.
OM-248663 Page 1
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
D
Check for noise level limits exceeding those specified by OSHA.
D
Use approved ear plugs or ear muffs if noise level is high.
D
Warn others nearby about noise hazard.
WELDING WIRE can injure.
D
Keep hands and body away from gun tip when trigger is pressed.
1-3.
Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
1-4.
Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
1-5.
EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit.
EMF fields can interfere with some medical implants, e.g. pacemakers.
Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1.
Keep cables close together by twisting or taping them, or using a cable cover.
2.
Do not place your body between welding cables. Arrange cables to one side and away from the operator.
READ INSTRUCTIONS.
D
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D
Use only genuine replacement parts from the manufacturer.
D
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and local codes.
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
3.
Do not coil or drape cables around your body.
4.
Keep head and trunk as far away from the equipment in the welding circuit as possible.
5.
Connect work clamp to workpiece as close to the weld as possible.
6.
Do not work next to, sit or lean on the welding power source.
7.
Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-248663 Page 2
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2015−09 fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.
2-1.
Signification des symboles
.
Indique des instructions spécifiques.
DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures personnelles.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.
2-2.
Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées dans le manuel d’utilisation du poste de soudage. Veuillez lire et respecter toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
D
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D
Prendre garde aux incendies et toujours avoir un extincteur à proximité.
D
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
L’ACCUMULATION DE VAPEURS peut causer des lésions ou la mort.
D
Quand on n’utilise pas le gaz comprimé de protection, fermer le robinet de la bouteille.
D
Assurer toujours la ventilation des zones fermées ou utiliser un appareil respiratoire avec alimentation en air.
UN CHOC ÉLECTRIQUE peut tuer.
D
Porter toujours des gants secs et isolants.
D
S’isoler de la pièce et de la terre.
D
Ne jamais toucher une électrode ou des pièces
électriques sous tension.
D
Remplacer les pistolets ou câbles de soudage qui sont endommagés, usés ou craquelés.
D
Mettre la soudeuse hors tension avant de remplacer un bec contact ou des pièces de pistolet.
D
S’assurer que tous les couvercles et poignées sont fermement assujettis.
Les PIÈCES MOBILES peuvent causer des blessures.
D
Ne pas s’approcher des organes mobiles.
D
Ne pas s’approcher des points de coincement tels que des rouleaux de commande.
LE RAYONNEMENT DE L’ARC peut brûler les yeux et la peau.
LES VAPEURS ET LES FUMÉES peuvent être nocives.
D
Éloigner sa tête des endroits renfermant des vapeurs.
D
Aérer la zone de travail ou porter un appareil respiratoire. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel.
D
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
LE SOUDAGE peut causer un incendie ou une explosion.
D
Ne pas souder à proximité de matériaux inflammables.
Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
D
Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D
Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
D
Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
OM-248663 Page 3
LES PIÈCES CHAUDES peuvent provoquer des brûlures.
D
Laisser refroidir le pistolet avant de le toucher.
D
Ne pas toucher d’objets métalliques chauds.
D
Abriter les objets métalliques contre tout contact par les personnes à proximité.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D
Éloigner les mains et le corps de la buse du pistolet après avoir appuyé sur la gâchette.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut affecter l’ouïe.
D
Vérifier si les niveaux de bruit excèdent les limites spécifiées par l’OSHA.
D
Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si le niveau de bruit est élevé.
D
Avertir les personnes à proximité au sujet du danger inhérent au bruit.
LIRE LES INSTRUCTIONS.
D
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.
D
N’utiliser que les pièces de rechange recommandées par le constructeur.
D
Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.
2-3.
Proposition californienne 65 Avertissements
Ce produit contient des éléments chimiques, dont le plomb, reconnus par l’État de Californie pour leur caractère cancérogène ainsi que provoquant des malformations congénitales ou autres problèmes de procréation. Se laver
les mains après toute manipulation.
Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre
25249.5 et suivants)
2-4.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
2-5.
Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ
électromagnétique (CEM) autour du circuit de soudage. Les champs
électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises:
Limiter par exemple tout accès aux passants ou procéder à une
évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
OM-248663 Page 4 from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
3 Ne pas courber et ne pas entourer les câbles autour de votre corps.
4 Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.
5 Connecter la pince sur la pièce aussi près que possible de la soudure.
6 Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.
7 Ne pas souder tout en portant la source de soudage ou le dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1.
Additional Safety Symbols And Definitions
.
Some symbols are found only on CE products.
3-2.
Miscellaneous Symbols And Definitions
U
V
1
Primary Voltage
Volts
A
X
Amperes
Duty Cycle
I
1
Notes
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
U
2
Conventional
Load Voltage
IP
Degree Of
Protection
Percent
Primary Current
I
2
Rated Welding
Current
OM-248663 Page 5
SECTION 4 − SPECIFICATIONS
4-1.
Gun Specifications
Model Welding Output Range
XR- Pistol - Plus Gun
(Air Cooled)
XR- Pistol - Plus Gun
(Water Cooled)
200 A at 100% Duty Cycle with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
400 A at 100% Duty Cycle with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
.
When using 1/16 in. (1.6 mm) wire, kit 230708 must be installed.
.
Instructions are for MPa Plus feeders with 14-pin gun connections.
Electrode
Wire Diameter
Capacity
.030 To 1/16 in.
(0.8 To 1.6 mm) aluminum wire
.030 To 1/16 in.
(0.8 To 1.6 mm) aluminum wire
Wire Feed
Speed Range
50 To 780 ipm
(1.3 To 19.8 mpm)
50 To 780 ipm
(1.3 To 19.8 mpm)
Net Weight
(Torch Only)
2.5 lb (1.1 kg)
(less cables)
2.9 lb (1.3 kg)
(less cables)
4-2.
Environmental Specifications
A. Temperature Specifications
Operating Temperature Range
14 to 104
°
F (−10 to 40
°
C)
Storage Temperature Range
−4 to 131
°
F (−20 to 55
°
C)
Temp_2016- 07
4-3.
Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
Air-Cooled Models
100% Duty Cycle At 200 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
OM-248663 Page 6
Continuous Welding
Water-Cooled Models
100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding sduty1 5/95
SECTION 5 − INSTALLATION
.
Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed.
5-1.
Equipment Connection Diagram - Single Feeder
1
1 Welding Power Source
2 Contactor Control/Power Cord
3 Positive (+) Weld Cable
4 Negative (−) Weld Cable
5 Workpiece
6 Welding Gun
.
Welding gun assembly shown is for MPa Plus feeder with
14-pin connection.
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder and Regulator
(Customer Supplied)
.
Shielding gas pressure not to exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water− cooled Guns Only
9
2
3
4
10
8
5
7
6
T0002-A
OM-248663 Page 7
5-2.
Equipment Connection Diagram - Dual Feeder
1
1 Welding Power Source
2 Contactor Control/Power Cord
3 Positive (+) Weld Cable
4 Negative (−) Weld Cable
5 Workpiece
6 Welding Gun
.
Welding gun assembly shown is for MPa Plus feeder with
14-pin connection.
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder and Regulator
(Customer Supplied)
.
Shielding gas pressure not to exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water− cooled Guns Only
9
4
3
2
10 8
5
7
OM-248663 Page 8
6
T0003-A
5-3.
14-Pin Plug Information For Connecting Wire Feeder To Power Source
Pin* Pin Information
11
12
13
*The remaining pins are not used.
14
9
10
3
4
1
2
5
6
7
8
Motor Common
Motor 0 to +24 volts DC with respect to pin 1
+5 volts DC tachometer power
Tachometer ref
Tachometer signal
Trigger
Trigger
Wire speed ref. +5 volts DC
Wire speed com
Wire speed 0 to +5 volts DC with respect to pin 9
Gun sensing resistor with respect to pin 9
Not used.
Not used.
Not used.
5-4.
Opening Top Cover Of XR - Pistol - Plus Gun
1
1 Top Cover Triangular Boss
Push up on triangular boss to open door. Door hinges on handle.
To open door fully, push up on door until it clicks into position.
.
If door is pushed too far it will separate from handle. If this happens the door can be reinstalled.
Push door back into original position to close.
T0004-A
OM-248663 Page 9
5-5.
Threading Welding Wire Through Gun
1
Refer to wire feeder manual for instructions on feeding wire through feeder.
1 Pressure Arm Lever
.
To release drive roll pressure, pull back on pressure arm lever.
While pulled back, shift to left onto shoulder to lock into place.
!
Welding wire is electrically live when gun trigger is used to jog wire.
.
Turn OFF coolant supply before removing head tube on water-cooled gun.
Tools Needed:
OM-248663 Page 10
Cut off wire. Close and latch wire feeder door.
Lay gun cable out straight. Press Jog switch until about 6 in. (152 mm) of wire is sticking out end of contact tip.
.
Verify pressure adjustment on handle matches the wire
Ref. T0001-A / T0005-A
6-1.
Gun Controls
SECTION 6 − OPERATION
1 Trigger
Press trigger to energize welding power source contactor (if applicable), start shielding gas flow, and begin wire feed.
Controls at the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released. When this feature is turned Off, no preflow or postflow is provided for the welding operation.
2 Wire Speed Control
Use control to adjust wire feed speed at the feeder. The numbers around the control are for reference only.
1
2
Ref. T0001-A
6-2.
Gun Pressure Roll Tension Setting
Tools Needed:
1
.
Aluminum series specific -
Pressure roll tension setting ensures smooth wire feeding action.
.
Gun Pressure Roll Tension is factory set to 4XXX.
1 Pressure Roll Adjustment
Screw
Wire tension should be set to 4XXX for 4000 series aluminum wire.
Rotate Pressure Roll Adjustment
Screw fully counterclockwise until indicator line on adjustment knob lines up with indicator line on handle in the 4XXX position.
Wire tension should be set to 5XXX for 5000 series aluminum and stainless wire.
Rotate Pressure Roll Adjustment
Screw fully clockwise until indicator line on adjustment knob lines up with indicator line on handle in the
5XXX position.
.
Small diameter (.035) 5000 series wire may run better on the 4XXX setting.
Ref. T0001-A / T0007
OM-248663 Page 11
6-3.
Shielding Gas
2
1
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before welding.
Gun trigger turns weld output and gas flow on and off (see Section
Close valve on cylinder when finished welding.
3 sb5.1 6/92 − S-0621-C / Ref. T0001-A
6-4.
Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot
Install &
Connect
Equipment
Put On
Personal Safety
Equipment
Set Controls
Turn On Gas
And Water (If
Applicable)
Turn On Feeder
And Welding
Power Source
Begin Welding ssb6.1* 9/92
6-5.
Coolant Supply For Water-Cooled Models Only
2
3
1
1 Coolant Supply
2 Coolant “In”
3 Coolant “Out”
See table below for coolant guidelines.
Turn On coolant supply before welding.
Turn Off coolant supply when finished welding.
Application
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
MILLER Aluminum Protecting
Coolant No. 043 809**;
Distilled Or Deionized Water OK
Above 32
°
F (0
°
C)
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37
°
F (-38
°
C) and resist algae growth.
OM-248663 Page 12
Ref. 150 755-A
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
Replace
Damaged Or
Unreadable
Labels
!
Disconnect power before maintaining.
3 Months
Replace
Damage
Gas Hose
.
Maintain more often during severe conditions.
Clean
And
Tighten
Weld
Terminals
Repair Or Replace
Cracked Cables
And Cords
6 Months
Blow Out Or
Vacuum Inside
Clean
Drive
Rolls
7-1.
Changing Gun Contact Tip
1
2
1 Nozzle
Unscrew nozzle.
2 Centerfire Contact Tip
Remove contact tip.
Install new contact tip.
NOTICE − Make sure correct size contact tip is being used. Incorrect size may cause arcing inside tip, poor feedability and poor arc starting characteristics(see Section 9).
.
Centerfire contact tips designed for aluminum wire have AL (Example T-047AL) as a designator at the end of the part number.
Reinstall nozzle.
Ref. 246 347-A
OM-248663 Page 13
7-2.
Replacing Head Tube Liner
3
2
2
1
.
Turn Off coolant supply before removing head tube on water-cooled gun.
The standard head tube liner will accommodate wire diameters from
.030-1/16 wire size.
When changing wire size, change gun drive roll.
1 Cover
2 Head Tube
Remove head tube from gun.
3 Liner
Pull liner out of head tube.
Insert new liner into head tube and reinstall head tube onto gun.
.
A twisting motion may be needed to feed liner thru head tube.
Ref. T0009-A
Notes
OM-248663 Page 14
7-3.
Replacing The Liner
1
4
Pistol Grip Gun
3
2
!
Turn Off wire feeder and welding power source.
1 Thumb Screw
2 Cone Guide
3 Collet Guide
4 Brass Guide Cap
Unscrew thumb screw.
Remove the following items:
S
Liner conduit assembly from handle.
S
Cone guide (rear of torch) and collet guide.
S
Brass guide cap from conduit assembly.
S
Old liner − pull from front of torch/ conduit.
Insert new liner in same direction as one removed (knurled ring towards front).
Tighten guide cap onto conduit.
Cut liner flush with front surface of collet.
Torque collet guide to 50 in lbs.
Reinstall guide cone, conduit and thumb screw.
Ref. T0010-A
OM-248663 Page 15
7-4.
Gun Drive Assembly Maintenance
2
1 Lever Arm
Remove pressure on wire by pulling lever arm forward. Pull to left to lock into place.
Retract wire onto spool.
2 Drive Roll
Use wire brush to clean drive roll.
Install drive roll with hex opening down toward shaft hex, and secure with screw.
3 Pressure Roll
Thread welding wire through gun.
Engage feeder drive rolls. Press jog switch until wire is sticking out end of contact tip.
Close top cover.
1
3
Tools Needed:
7/64, 1/16 in.
3/8 in.
OM-248663 Page 16
Ref. T0008-A
7-5.
Troubleshooting Table
!
Disconnect power before troubleshooting.
Trouble Remedy
No wire feed at gun, feeder not operating. Check motor or brake solenoid.
Reset circuit breaker at power source. See power source owner’s manual.
Replace trigger-switch and test operation.
Check trigger-switch wires for continuity.
No wire feed at gun, feeder operating properly.
Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s manual.
Check potentiometer with meter and replace if necessary.
Check motor and potentiometer wires for continuity.
See feeder/control owner’s manual.
Wire feeds, but welding wire is not energized.
Clean and tighten all power connections.
See feeder/control owner’s manual.
Wire feeds erratically.
Check operation of welding power source.
Check conduit for wear and obstruction and replace if necessary.
Check contact tip for correct size and replace if necessary.
Check pressure roll tension setting (see Section 6-2).
Check for proper head tube liner (see Table 9-7).
Check potentiometer with meter and replace if necessary.
Wire feeds one speed only.
Check continuity of welding gun wire feed speed potentiometer and replace if necessary.
See feeder/control owner’s manual.
Pressing gun trigger does not energize feeder. Welding wire is not energized.
Shielding gas does not flow.
Secure plug from gun control cable into gun control receptacle on feeder.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Wire feeds, shielding gas flows, but welding wire is not energized.
See Troubleshooting section in welding power source manual.
OM-248663 Page 17
OM-248663 Page 18
SECTION 8 − ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram For XR - Pistol - Plus Gun
Ref. 256010-C
Notes
OM-248663 Page 19
SECTION 9 − PARTS LIST
38
37
36
35
33
34
70
39
34
13
15
31
40
19
41
51
50
53
56
55
54
58
57
52 49
60
61
48
47
46
45
44
43
71
68
59
69
67 66
65
1
62
63
64
32
30
17
16
14
42
29
22
27
28
18
23
21
26
25
24
25
17
16
15
14
13
12
18
20
7 8
9
72
10
11
6
.
Hardware is common and not available unless listed.
5
Figure 9-1. Exploded View Of XR - Pistol - Plus Gun
4
3
1
2
T0011-D
OM-248663 Page 20
Item
No.
Part
No.
Description
Figure 9-1. Exploded View Of XR - Pistol - Plus Gun
Quantity
38
39
40
41
33
34
35
36
37
27
28
29
30
31
32
21
22
22
23
24
24
24
25
25
25
26
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
16
17
17
17
18
18
18
19
19
19
20
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
15
15
15
16
16
12
13
14
14
14
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
1 . . . . . . . . . . . . . .
. .
2 . . . . . . . . . . . . . .
. .
3 . . . . . . . . . . . . . .
. .
4 . . . . . . . . . . . . . .
. .
5 . . . . . . . . . . . . . .
. .
6 . . . . . . . . . . . . . .
. .
7 . . . . . . . . . . . . . .
. .
8 . . . . . . . . . . . . . .
. .
9 . . . . . . . . . . . . . .
. .
. .
10
11
. . . . . . . . . . . . .
. . . . . . . . . . . . .
257353
000369
183884
184101
217934
134856
602169
. .
. .
. .
. .
. .
. .
. .
Kit, Handle XR Pistol Pro/Plus
Limit Switch 10A
Screw, Set Stl Sch 8-32 X .187
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, Cprsn .300 Od X .026 Wire X 1.250
. . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Shldr.140Id 0.250Odx.047T .340Odx.078T Nyl
Screw, K40x 20 Pan Hd-Trx Stl Pld Pt Thread Forming
Knob, Speed Control 1-10 .140 Shaft X 1.125 Od
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
248333
200096
. .
. .
Pistol Plus Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, C Sltd Sft 1/T .5W 10K Ohm . . . . . . . . . . . . . . . . . . . . . . . . . .
175731
135127
. .
. .
Washer, Anti-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lock, Shaft Pot .250-32 X .125Dia Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
135580
149332
191072
248361
248376
. .
. .
. .
. .
. .
Fitting, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, Hose .405 − .485 Clp Dia
Hose, Water In 15Ft
Hose, Water In 25Ft
Hose, Water In 35Ft
. . . . . . . . . . . . . . . . . . . . . . . . . . .
1 A/C, 2 W/C
2 A/C, 3 W/C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
191058
248356
. .
. .
Hose, Gas In 15Ft
Hose, Gas In 25Ft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
248371
M1114
. .
. .
Hose, Gas In 35Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit/Liner Assembly, 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
248357 . .
Conduit/Liner Assembly, 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
248372
M1115
248359
248375
232055
M1619
M1620
M1621
. .
. .
. .
. .
. .
. .
. .
. .
Conduit/Liner Assembly, 35 Ft
Cable, Power/Water Out 35Ft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner,.175−.180 Od X .120 Id Hi Lube 15’ Gun W/Rng
Liner,.175−.180 Od X .120 Id Hi Lube 25’ Gun W/Rng
Liner,.175−.180 Od X .120 Id Hi Lube 35’ Gun W/Rng
191052 . .
Cable, Power/Water Out 15Ft
228696 . .
Cable, Power/Water Out 25Ft
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Control 15Ft - Pistol Plus
Cable, Control 25Ft - Pistol Plus
Cable, Control 35Ft - Pistol Plus
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
235751 . .
Tubing, Silicone Rbr .500 Id X Spool Black . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
3
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
235225
M1570
238875
227449
236764
248355
. .
. .
. .
. .
. .
. .
Strip, Cop .010 X 1.500 X .750
Strain Relief, Cable (Air)
Strain Relief, Molded (Water)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacket, Cable 2 Ft 4 In (Power Pin)
Cable Cover, Leather W/Velcro 15Ft
Cable Cover, Leather W/Velcro 25Ft
248377 . .
Cable Cover, Leather W/Velcro 35Ft
235831 . .
Cable, Power 15Ft (Air) - Pistol Plus
248381 . .
Cable, Power 25Ft (Air) - Pistol Plus
248386 . .
Cable, Power 35Ft (Air) - Pistol Plus
152577 . .
Strip, Copper .010 X 2.000 X .750
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
137495
141694
246119
203560
203539
189812
. .
. .
. .
. .
. .
. .
Fitting, Connection Power Weld
Spring, Strain Relief
Strain Relief, Spring Retainer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, Set 312-18 X .37 Conept Sch Stl Pln
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, Liner Double Wound Adapter
Housing, Power Pin Rh
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
196177
202513
. .
. .
Hose, Water Out 10 in.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 . . . . . . . . . . . . . . .
1
1 A/C, 2 W/C
193896
079974
229852
. .
. .
. .
Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, .500 Id X .103 Cs Rbr
Guide, Collet Outlet .030-1/16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
M1102
187029
189811
203557
. .
. .
. .
. .
Guide, Cone Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Power/Gas
Housing, Power Pin Lh
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, 1−Ear Type Nom Dim .391 X .236 Wide Special . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
OM-248663 Page 21
Item
No.
Diagram marking
Part
No.
Description
Figure 9-1. Exploded View Of XR - Pistol - Plus Gun (Continued)
Quantity
42
42
43
43
44
45
46
47
. .
. .
. .
. .
. .
. .
. .
. .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
258474
258475
. .
. .
Kit, Head Tube Assy (Air) AP/PP 180Deg 4In. Lg Cntrfr . . . . . . . . . . . . . . . .
Kit, Head Tube Assy (Water) AP/PP 180Deg 4In. Lg Cntrfr . . . . . . . . . . . . .
248329
248388
. .
. .
W/C Pistol Block Assy
A/C Pistol Block Assy
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M1154
227434
. .
. .
Screw, 008-32 X .625 Soc Hd-Hex Stl Pld Lkg Patch
Drive Roll Knurled
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
226588
248466
. .
. .
Screw, 010-32 X .37 Btn Hd-Soc Sst Lkg Patch
Screw, 18-8 Hex Socket Shld 6-32 Thread
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
48 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. .
. .
. .
49
50
51
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
155565
134799
. .
. .
Screw, Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, .176 Id X .070 Cs (Used W/Thumbscrew) . . . . . . . . . . . . . . . . . . . . .
134624
227435
. .
. .
Washer Shldr .141 Id 0.187 Od X .094T .375 Od X .031T Nyl
Arm, Pressure (Machined)
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
231443 . .
Screw, 006-32 X .44 Soc Hd-Hex Grd 8 Pld Lkg Patch . . . . . . . . . . . . . . . . .
52
53
54
55
56
57
62
63
64
65
66
58
59
59
60
61
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
227439
227421
229850
M1376
229851
005464
235753
234971
078753
136679
129351
191121
164592
M1614
M1358
M1124
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
Drive Roll Assy, Idler .645 Od
Spring, Crspn .360 Od X .059 Wire X .440 Free
Washer, Pressure Arm Precision
Knob, Tension Pistol Pro/Plus 8-32 Thd
Nut, Pressure Arm Plastic
Ftg, Connection Power Weld
Clamp, Strain Relief
Trigger
Set Screw 6-32 X .625
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, Set 250−20x .37 Ovl Pt Sch Stl Pln Nylok . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, Set 250−20x .31 Conept Sch Stl W/Nyl Patch (Air)
Screw, Set 250−20x .31 Cup Pt Sch Stl Pln
Screw, 008-32 X .50 Hexwhd .34D W/Spl Gndrng Stl Pld
Screw, 006-32 X .37 Btn Hd-Soc Stl Pld
Motor Assembly - Pistol Plus Guns
Lever, Arm Assy Pistol Plus/Pro
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
. .
. .
. .
. .
67
68
69
70
71
71
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
248328
M1106
227429
089120
M1415
M1452
. .
. .
. .
. .
. .
. .
Motor Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistol Plus Manifold Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, 004-40 X .25 Rnd Hd-Phl Stl Pld Lkkg Patch
Clamp, Hose .375 - .450 Clp Dia Slfttng Green
Kit, Manifold Block−Air Pistol Pro/Plus
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Manifold Block−Water Pistol Pro/Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
. .
72 . . . . . . . . . . . . .
M1460 . .
O-Ring, .143 Id X .349 Od X .103 Cs, Buna-N . . . . . . . . . . . . . . . . . . . . . . . .
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
OM-248663 Page 22
.
Hardware is common and not available unless listed.
2
3
4
1
5
6
8
9
8
10
11
7
T0012
Item
No.
Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Plus Gun
Part
No.
Description
Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Plus Gun
Quantity
. . . . . . . . . . . . . . . .
. . .
1
258475
. . . . . . . . . . . . .
3414
. .
. .
Kit, Head Tube Assy (Water) AP/PP 180Deg 4In. Lg Cntrfr
Nozzle Cone, Cf Hd, 3/4 in. Id 1/4 in. Rec
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
2 . . . . . . . . . . .
. . .
7 . . . . . . . . . .
. . . . . . . . . . . . . . . .
N-HDC . .
Hd Centerfire Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
3 . . . . . . . . .
. . .
4 . . . . . . . . . . .
. . .
. . .
5
6
. . . . . . . . . .
. . . . . . . . . . .
T-047AL . .
Contact Tip, Centerfire .047 Aluminum
D-1AP
232284
. .
. .
Diffuser, Centerfire-D-1AP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Nozzle Collared Diffuser (For 180
°
/Straight Only)
M1369 . .
Insulator, Head Tubes Aluma/Pistol Pro W/C 4 in.
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
229889
230970
. .
. .
Nut, Head Tube Rotation Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Replacement O-Rings Head Tube Water (Includes) . . . . . . . . . . . . . . . . . .
. . .
8 . . . . . . . . . .
. . .
9 . . . . . . . . . .
. . .
10 . . . . . . . . . . .
. . .
11 . . . . . . . . . . .
194261
210771
. . . . .
. . . . .
O−Ring, .551 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, 14.99mm Id X 1.27mm Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . .
191191
M1442
. . . . .
. .
O−Ring, .312 Id X .070 Cs 70 Duro Buna−n
Liner, Teflon .047−.062 Wire Soft Pro/Plus
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
2
1
1
1
1
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-248663 Page 23
.
Hardware is common and not available unless listed.
1
2
3
4
5
7
8
6
T0013
Item
No.
Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Plus Gun
Part
No.
Description
Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Plus Gun
Quantity
. . . . . . . . . . . . . . . .
. . .
. . .
1
2
. . . . . . . . .
. . . . . . . . .
258474 . .
Kit, Head Tube Assy (Air) AP/PP 180Deg 4In. Lg Cntrfr . . . . . . . . . . . . . . . . . .
N-5818C
T-047AL
. .
. .
Nozzle, C−Fire Large Copper 5/8in. Recess 1/8in.
Contact Tip, Centerfire .047 Aluminum
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
3
4
. . . . . . . . . . .
. . . . . . . . . .
. . .
5 . . . . . . . . . . .
. . .
6 . . . . . . . . . .
D-1AP
232284
. .
. .
Diffuser, Centerfire-D-1AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Nozzle Collared Diffuser (For 180
°
/Straight Only) . . . . . . . . . . . . . . .
M1366 . .
Insulator, Head Tubes Aluma/Pistol Pro A/C 4 in.
. . . . . . . . . . . . . . . . . . . . . . . .
227168 . .
Nut, Head Tube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . .
7 . . . . . . . . . . .
. . .
8 . . . . . . . . . . .
230969
191191
. .
Kit, Replacement O-Rings Head Tube Air (Includes)
. . . .
O-Ring, .312 Id X .070 Cs 70 Duro Buna−n
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
M1442 . .
Liner, Teflon .047−.062 Wire Soft Pro/Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-248663 Page 24
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES
Item
Number
1 2 3 4 5
HEAD TUBES
A/C 180 Straight
Centerfire
Nozzles
N − 5818C
2 pc (3414 − N-HDC)
Centerfire
Contact Tips
T − 035AL
T − 047AL
T − 062AL
Centerfire
Diffusers
D − 1AP
A/C OUTER
180
(M1366)
W/C OUTER
180
(M1369)
COLLARED
INSULATOR
258 474
W/C 180 Straight
258 475
(232 284)
Ref. 803 909-A / T0014 / T0015
Figure 10-1. Consumables Flowchart
Item
No.
Part
No.
Description
Quantity
Table 10-1. Centerfire Nozzles
. . .
. . .
1
1
. . . . . . . . .
. . . . . . . . .
N−5818C
N−3414C
. .
. .
Nozzle, C-Fire Large Copper 5/8 in. Recess 1/8 in. (Std. For A/C)
Nozzle, C-Fire Large Copper 3/4 in. Recess 1/4 in. (Std. For W/C)
. . . . . . . . .
. . . . . . . .
. . .
1 . . . . . . . . . .
N−HDC . .
HD Centerfire Nozzle Body (Std. For W/C)
. . .
1 . . . . . . . . . . . . .
3414 . .
Nozzle Cone, Cf Hd, 3/4 in. Id 1/4 in. Rec
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
Table 10-2. Centerfire Contact Tips*
. . .
. . .
2
2
. . . . . . . . .
. . .
2 . . . . . . . . .
. . . . . . .
T−035AL
T−047AL
. .
. .
Centerfire Contact Tip .035 (0.9mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . . .
Centerfire Contact Tip 3/64 in. (1.2mm) Aluminum Wire
♦
T−062AL . .
Centerfire Contact Tip 1/16 in. (1.6 mm) Aluminum Wire
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
1
1
1
Table 10-3. Centerfire Diffusers
. . .
3 . . . . . . . . . . .
D−1AP . .
Diffuser, Centerfire D−1AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Table 10-4. Insulators
. . .
4 . . . . . . . . . . .
. . .
4 . . . . . . . . . . .
. . .
4 . . . . . . . . . .
M1366 . .
Insulator, Head Tubes Aluma/Pistol Pro A/C 4 In.
M1369 . .
Insulator, Head Tubes Aluma/Pistol Pro W/C 4 In.
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
232284 . .
Insulator, Nozzle Collared Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
OM-248663 Page 25
Table 10-5. Head Tube Assemblies
. . .
5 . . . . . . . . . .
. . .
5 . . . . . . . . . .
258474 . .
Kit, Head Tube Assy (A) AP/PP 180Deg 4In. Lg Cntrfr
258475 . .
Kit, Head Tube Assy (W) AP/PP 180Deg 4In. Lg Cntrfr
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
1
1
Table 10-6. FasTip Head Tube Liners (Not Shown)
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
M1441 . .
Liner, Teflon .035−.045 Wire Soft Pro/Plus
M1442 . .
Liner, Teflon .047−.062 Wire Soft Pro/Plus
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
Table 10-7. Wire Kit (Not Shown)
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
♦
230708 . .
. .
Kit, Idler Roll 1/16 (.062) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦
198377 Hardwire Liner Kit, 30W For Steel&Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
♦
OPTIONAL
*All contact tips are packaged in bags of 25.
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.
OM-248663 Page 26
Warranty Questions?
Call
1-800-4-A-MILLER for your local
Miller distributor.
Your distributor also gives you ...
Service
You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Support
Need fast answers to the tough welding questions?
Contact your distributor.
The expertise of the distributor and Miller is there to help you, every step of the way.
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
This limited 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 below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. If notification is submitted as an online warranty claim, the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.
1.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
2.
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
3.
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
4.
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
5.
6 Months — Parts
* Batteries
6.
90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
*
*
*
*
*
Non-Electronic Controls
M-Guns
MIG Guns, Subarc (SAW) Torches, and External
Cladding Heads
Remote Controls and RFCS-RJ45
Replacement Parts (No labor)
Spoolmate Spoolguns
Miller’s True Blue
®
Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)
2.
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.
3.
Equipment that has been modified by any party other than
Miller, or equipment 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 COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, 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 F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT 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
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, 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, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 2017-01
Owner’s Record
Please complete and retain with your personal records.
Serial/Style Number Model Name
Purchase Date
Distributor
Address
City
State
(Date which equipment was delivered to original customer.)
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Contact the Delivering Carrier to:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller
File a claim for loss or damage during shipment.
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
©
2017 Miller Electric Mfg. Co. 2017−01
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
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