Miller | MD311616T | Owner Manual | Miller XR - PISTOL - PRO User manual

Miller XR - PISTOL - PRO User manual
OM-254 824H
2013−07
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air/WaterCooled, MIG (GMAW) Welding
Gun
™
XR - Pistol - Pro
(Air And Water-Cooled Guns)
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
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 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-3. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-5. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4-1. Gun Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5-1. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding
Power Source Having A 14-Socket Receptacle Or A Integrated Welding Power Source Having A
10-Socket Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5-2. Air-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
5-3. Water-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
5-4. Millermatic 350/350P Water Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-5. Threading Welding Wire Through Millermatic 350/350P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-6. Threading Welding Wire Through XR-Control Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-7. Adjusting Tension At Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-8. 10-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-9. Removing Top Cover Of Pistol Grip Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-10. Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-1. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-2. Gun Pressure Roll Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-3. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-4. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-5. Coolant Supply For Water-Cooled Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7-1. Replacing The Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7-2. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7-3. Gun Drive Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7-4. Replacing Head Tube Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-5. Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
WARRANTY
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2011-10
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 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.
. Indicates special instructions.
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.
1-2. Arc Welding Hazards
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.
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.
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 Repair or replace worn, damaged, or cracked gun or cable insulation.
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.
D Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for material
used.
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.
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.
D Wear welding helmet with correct shade of filter.
D Wear correct eye and body protection.
D Cover exposed skin with spatter-resistant
clothing.
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.
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.
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 maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OM-254 824 Page 1
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.)
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.
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 Protection, 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 Combustibles, 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,
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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, 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).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may 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:
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.
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.
3. Do not coil or drape cables around your body.
OM-254 824 Page 2
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.
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2011−10fre
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
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.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
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.
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 Réparer ou remplacer un pistolet ou la gaine d’isolement d’un
câble usée, endommagée ou fissurée.
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.
LE SOUDAGE peut causer un incendie ou une explosion.
D Ne pas souder à proximité de matériaux inflammables.
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.
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.
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.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
LE RAYONNEMENT DE L’ARC peut
brûler les yeux et la peau.
D Éloigner sa tête des endroits renfermant des
vapeurs.
D Aérer la zone de travail ou porter un appareil respiratoire.
D Consulter les fiches toxicologiques (MSDS) et les notices du fabricant de chaque matériel utilisé.
D Porter un casque de soudage muni d’un filtre
de protection oculaire approprié.
D Porter une protection oculaire et des vêtements de protection appropriés.
D Protéger la peau nue en portant des vêtements anti-éclaboussures.
OM-254 824 Page 3
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
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.
D Éloigner les mains et le corps de la buse du pistolet après avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
Le BRUIT peut endommager l’ouie.
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’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
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.
2-3. Proposition californienne 65 Avertissements
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)
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.
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 Protection, 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 Combustibles, 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,
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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, 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).
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. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des 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:
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.
1
Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
En ce qui concerne les implants médicaux :
2
Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3
Ne pas courber et ne pas entourer les câbles autour de votre
corps.
OM-254 824 Page 4
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.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
3-2. Miscellaneous Symbols And Definitions
U1
IP
Primary Voltage
Degree Of
Protection
V
U2
Volts
Conventional Load
Voltage
I1
I2
Primary Current
Rated Welding
Current
A
X
Amperes
Duty Cycle
Percent
Notes
OM-254 824 Page 5
SECTION 4 − SPECIFICATIONS
4-1. Gun Specifications
Model
Welding Output Range
Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
(Torch Only)
XR-Pistol-Pro
(Air-Cooled)
200 A at 100% Duty Cycle
250 A at 60% Duty Cycle
15ft, 25ft or 35ft
(4.6m, 7.6m or 10.7m) guns
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.2 lb (1 kg)
(less cables)
XR-Pistol-Pro
(Water-Cooled)
400 A at 100% Duty Cycle
15ft, 25ft or 35ft
(4.6m, 7.6m or 10.7m) guns
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.4 lb (1.08 kg)
(less cables)
. When using 1/16 in. (1.6 mm) wire, kit 230708 must be installed.
4-2. 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 Amperes Using Argon
Continuous Welding
60% Duty Cycle At 250 Amperes Using Argon
6 Minutes Welding
4 Minutes Resting
Water-Cooled Models
100% Duty Cycle At 400 Amperes Using Argon
Continuous Welding
sduty1 5/95
OM-254 824 Page 6
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. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage
(CC/CV) Welding Power Source Having A 14-Socket Receptacle Or A Integrated
Welding Power Source Having A 10-Socket Receptacle
9
1
2
7
8
6
3
9
10
5
1
4
10
5
Ref. T0018 / T0019
1
2
3
4
CV Or CC/CV Welding Power Source
24 VAC/Contactor Control 14-Pin
Plug
Negative (−) Weld Cable
Workpiece
5
6
7
8
9
Welding Gun
Wire Feeder
Positive (+) Weld Cable
Gas Hose
Gas Cylinder
. Shielding gas pressure not to exceed
100 psi (689 kPa).
10 Gun Control Cable 10-Pin Plug
OM-254 824 Page 7
5-2. Air-Cooled Gun Connections
4
5
Left Side
3
2
Ref. T0017 / 246 218-A
1
1 Gun Control Cable
Insert plug into Gun Control receptacle, and
tighten threaded collar.
2 Gun Power Pin
OM-254 824 Page 8
3
Gun Bushing
4
Gun Securing Knob
5
Drive Casting
Loosen gun securing knob and insert gun
power pin through gun bushing until it
bottoms against drive casting. Tighten
knob.
5-3. Water-Cooled Gun Connections
. Turn on coolant supply before
welding or gun will be damaged.
1
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
3
4
2
3
4
5
Loosen gun securing knob, and
insert gun power pin through gun
bushing until it bottoms against
drive casting. Tighten knob. Close
and latch door.
6
5
Gun Power Pin
Gun Securing Knob
Gun Bushing
Drive Casting
Gun (Coolant) “In” Hose
Connect to Water “Out” fitting on
feeder (left-hand threads).
7
Gun (Coolant) “Out” Hose
Connect to Water “In” fitting on
feeder (left-hand threads)
Left Side
8
8
9
10
11
9
Water Cooler Output
Water Cooler Input
Feeder (Coolant) Output
Feeder (Coolant) Input
10
11
4
7
Tools Needed:
9/16 in.
1
2
6
Ref. T0020 / 246 218-A
OM-254 824 Page 9
5-4. Millermatic 350/350P Water Cooled Gun Connections
8
7
1
2
Ref. T0021
6
5
3
4
Tools Needed:
9/16 in.
. Turn on coolant supply before welding
or gun will be damaged.
1 Coolant Supply
2 Millermatic 350P
3 Gun Control Cable
Insert plug into gun control receptacle and
tighten threaded collar.
OM-254 824 Page 10
4
Water In Hose
Connect to coolant supply with supplied
coupler and water hose (left-hand threads).
5
Gun Connector
Loosen gun securing knob, and insert gun
connector through Wire opening until it
bottoms against block. Tighten knob. Close
and latch door.
6 Water Out Hose
Connect to coolant supply with supplied
coupler and water hose (left-hand threads).
7 Coolant “In”
8 Coolant “Out”
5-5. Threading Welding Wire Through Millermatic 350/350P
1
2
3
4
5
6
7
8
7
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
Lay gun cable out straight.
Tools Needed:
8
1
2
3
4
5
6
. Hold wire tightly to keep it
IMPORTANT!
For Aluminum Push-Pull welding.
Thread hub tension nut loosely
from unraveling.
6 in.
(150 mm)
218243-A
3/4 in.
Pull and hold wire; cut off end.
Open pressure assembly.
IMPORTANT!
For Aluminum
Push-Pull welding.
Tighten to
1/2 lb.
1
2
3
4
Push wire thru guides into gun;
continue to hold wire.
Pressure
Indicator
Scale
2
43
1
218244-A
Close and tighten pressure
assembly, and let go of wire.
. Set pressure indicator
scale to 1/2 lb.
See Section 5-10 for threading welding wire through XR guns.
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
OM-254 824 Page 11
5-6. Threading Welding Wire Through XR-Control Feeder
1
Cable Assembly
Lay cable assembly out straight.
2
Tools Needed:
2
Jog Switch
Push Jog switch up to feed wire through
cable assembly.
3
Torque Switch
. Select proper push feeder torque set-
3
ting for wire size being used. Use low
torque for .030 in. (0.8mm) wire. Use
high torque for all other wire sizes.
. XR-AlumaFeed torque setting is automatically set internally for wire sizes.
JOG / PURGE
1
Ref. 246 218-A / 805 354
Notes
OM-254 824 Page 12
5-7. Adjusting Tension At Feeder
1
Tools Needed:
. Hold wire tightly to keep
it from unraveling.
6 in.
(150 mm)
1
Pull and hold wire; cut off end.
Tension Arm
Open tension arm.
1
Install proper size drive rolls.
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension as
follows:
Tension Settings
Wire Size
Welding
0.030 - 0.035 in.
1−2
0.040 in.
3/64 in.
Gun Calibration
3−4
3−4
1/16 in.
Ref. 805 350-A / 242 517-A
OM-254 824 Page 13
5-8. 10-Pin Plug Information
10
E
D
F
J
G
I
C
H
B
A
Pin*
Pin Information
A
Electrode sense lead
B
Motor 0 to +24 volts DC with respect to pin C
G
Trigger
C
Motor Common
D
Trigger
E
Wire speed Ref. +9 volts DC
H
Wire speed com
F
Wire speed 0 to +9 volts DC with respect to pin H
J
Gun sensing resistor with respect to pin H
I
Not used
5-9. Removing Top Cover Of Pistol Grip 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.
T0022
OM-254 824 Page 14
5-10. Threading Welding Wire Through Gun
Refer to wire feeder manual for instructions on
feeding wire through feeder.
1
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.
JOG / PURGE
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
type. See Section 6-2.
Tools Needed:
Cut off wire. Close and latch
wire feeder door.
Ref. T0006 / T0022 / T0023
OM-254 824 Page 15
SECTION 6 − OPERATION
6-1. Gun Controls
1
Trigger
Press trigger to energize welding
power source contactor
(if applicable), start shielding gas
flow, and begin wire feed.
2
Wire Speed Control
Use control to fine adjust wire feed
speed set on wire feeder Weld
Speed control. The numbers
around the control are for reference
only.
1
2
Ref. T0023
6-2. Gun Pressure Roll Tension Setting
. Aluminum
series specific Pressure roll tension setting
ensures smooth wire feeding
action.
. Gun Pressure Roll Tension is
factory set to 4XXX.
1
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
Tools Needed:
diameter (.035) 5000
series wire may run better on
the 4XXX setting.
Ref. T0023
OM-254 824 Page 16
6-3. Shielding Gas
1
2
3
Shielding Gas Cylinder
Valve
Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off (see Section
6-1).
2
1
Close valve on cylinder when
finished welding.
3
sb5.1 6/92 − S-0621-C / Ref. 151 666-F
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
1
2
3
Coolant Supply
Coolant “In”
Coolant “Out”
See table below for coolant
guidelines.
1
3
Turn On coolant supply before
welding.
Turn Off coolant supply when
finished welding.
2
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.
Ref. 150 755-A
OM-254 824 Page 17
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
!
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Clean
And
Tighten
Weld
Terminals
Replace
Damage
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Blow Out Or
Vacuum Inside
Clean
Drive
Rolls
7-1. Replacing The Liner
1
!
Turn Off wire feeder and
welding power source.
1
2
3
4
Thumb Screw
Cone Guide
Collet Guide
Brass Guide Cap
Unscrew thumb screw.
Remove the following items:
S Liner conduit assembly from
handle.
4
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.
2
Pistol Grip Gun
3
Insert new liner in same direction as
one removed (knurled ring towards
front).
Tighten Brass guide cap onto conduit.
Torque collet guide to 50 in. lbs.
Cut liner flush with front surface of
collet guide.
Reinstall guide cone, conduit and
thumb screw.
Ref. T0024
OM-254 824 Page 18
7-2. Changing Gun Contact Tip
Remove nozzle
1
Nozzle
2
FasTip
Unscrew FasTip.
Install new FasTip.
2
Ref. 150 437-A
1
7-3. Gun Drive Assembly Maintenance
1
Lever Arm
Remove pressure on wire by
pulling lever arm forward. Pull to left
to lock into place.
Retract wire onto spool.
2
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.
Ref. T0008 / T0025
OM-254 824 Page 19
7-4. Replacing Head Tube Liner
. Turn Off coolant supply before
removing head
water-cooled gun.
tube
on
The standard head tube liner
(yellow) will accommodate wire
diameters from 3/64 in. - 1/16 in.
wire size.
3
When changing wire size, change
gun drive roll.
1
1
2
Cover
Head Tube
Remove head tube from gun.
2
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 need-
ed to feed liner thru head tube.
2
Ref. T0026
7-5. Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns
1
2
3
Ref. T0027
Air Cooled Head Tube Assembly
Tools Needed:
3/8 in.
!
Turn Off welding power source and
water supply.
!
Water in gun parts can cause electric shock and can lower weld quality.
OM-254 824 Page 20
Always point gun downward when
removing water-cooled barrel to
keep water out of gun parts.
Wipe gun dry before putting it back
together.
1 Nozzle
2 FasTip
To remove, see Section 7-2.
3 Diffuser
Remove diffuser and replace.
7-6. Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Remedy
Pressing gun trigger does not energize Secure plug from gun control cable into Gun Control receptacle on feeder
feeder. Welding wire is not energized. (see Section 5-2 or 5-3 as applicable).
Shielding gas does not flow.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Wire feeds, shielding gas flows, but See Troubleshooting section in welding power source manual.
welding wire is not energized.
Wire feeds erratically.
Adjust drive roll pressure if necessary (see Section 5-6).
Clean or replace drive rolls as necessary (see Section 7-3).
Check and replace liner if necessary (see Section 7-4).
No weld output; gun/feeder does not Check gun trigger plug connection on wire feeder front panel (see Sections 5-2 and 5-3).
work.
Place Power switch on welding power source in the On position.
Erratic weld output.
Tighten and clean all connections.
Check drive roll pressure in wire feeder and gun (see Section 5-6).
Check and replace liner if necessary (see Section 7-4).
Wire does not feed; burnback in contact Check drive roll pressure in wire feeder and gun (see Section 5-6).
tip.
Check and replace liner if necessary (see Section 7-4).
Reinstall voltage sensing lead (see Section 5-1).
Gun
overheating
models).
(water-cooled Be sure coolant flow rate is at least 1 qt/min.
Corrosion buildup in gun decreasing coolant flow rate. Backflush coolant system, clean coolant system
filter, and clean fittings.
OM-254 824 Page 21
Notes
OM-254 824 Page 22
SECTION 8 − ELECTRICAL DIAGRAMS
Ref. 256 014-C
Figure 8-1. Circuit Diagram For XR Pistol Pro Gun
Notes
OM-254 824 Page 23
SECTION 9 − PARTS LIST
38
37
56
55
54
53
50
19
58
57
36
35
40
39
1
51
52 49
60 61
62
63
34
34
65
59
13
48
15
70
47
31
33
46 45
44
69
43
64
67 66
71
41
32
68
17
30
16
14
42
29
22
18
23
21
25
27
28
18
26
17
16
20
25
15
14
24
13
12
7
8
9 72
11
10
1
6
2
. Hardware is common and
not available unless listed.
5
3
T0028-C
Figure 9-1. Exploded View Of XR - Pistol - Pro Gun
OM-254 824 Page 24
4
Item
No.
Part
No.
Description
Quantity
Figure 9-1. Exploded View Of XR - Pistol - Pro Gun
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1 . . . . . . . . . . . . . 257 353
2 . . . . . . . . . . . . . 000 369
3 . . . . . . . . . . . . . 183 884
4 . . . . . . . . . . . . . 184 101
5 . . . . . . . . . . . . . 217 934
6 . . . . . . . . . . . . . 248 333
7 . . . . . . . . . . . . . 200 096
8 . . . . . . . . . . . . . 175 731
9 . . . . . . . . . . . . . 135 127
10 . . . . . . . . . . . . 134 856
11 . . . . . . . . . . . . 602 169
12 . . . . . . . . . . . . 135 580
13 . . . . . . . . . . . . 149 332
14 . . . . . . . . . . . . 191 072
14 . . . . . . . . . . . . 248 361
14 . . . . . . . . . . . . 248 376
15 . . . . . . . . . . . . 191 058
15 . . . . . . . . . . . . 248 356
15 . . . . . . . . . . . . 248 371
16 . . . . . . . . . . . . . M1114
16 . . . . . . . . . . . . 248 357
16 . . . . . . . . . . . . 248 372
17 . . . . . . . . . . . . . M1115
17 . . . . . . . . . . . . 248 359
17 . . . . . . . . . . . . 248 375
18 . . . . . . . . . . . . 191 052
18 . . . . . . . . . . . . 228 696
18 . . . . . . . . . . . . 232 055
19 . . . . . . . . . . . . . M1269
19 . . . . . . . . . . . . . M1245
19 . . . . . . . . . . . . . M1246
20 . . . . . . . . . . . . 235 751
21 . . . . . . . . . . . . 235 225
22 . . . . . . . . . . . . 133 362
22 . . . . . . . . . . . . 238 875
23 . . . . . . . . . . . . 227 449
24 . . . . . . . . . . . . 236 764
24 . . . . . . . . . . . . 248 355
24 . . . . . . . . . . . . 248 377
25 . . . . . . . . . . . . 235 831
25 . . . . . . . . . . . . 248 381
25 . . . . . . . . . . . . 248 386
26 . . . . . . . . . . . . 152 577
27 . . . . . . . . . . . . 137 495
28 . . . . . . . . . . . . 141 694
29 . . . . . . . . . . . . 203 562
30 . . . . . . . . . . . . 203 560
31 . . . . . . . . . . . . 203 539
32 . . . . . . . . . . . . 189 812
33 . . . . . . . . . . . . 196 177
34 . . . . . . . . . . . . 202 513
35 . . . . . . . . . . . . 193 896
36 . . . . . . . . . . . . 079 974
37 . . . . . . . . . . . . 229 852
38 . . . . . . . . . . . . . M1102
39 . . . . . . . . . . . . 187 029
40 . . . . . . . . . . . . 189 811
41 . . . . . . . . . . . . 203 557
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Kit, Handle XR Pistol Pro/Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Limit Switch 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, Cprsn .300 Od X .026 Wire X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Shldr.140Id 0.250Odx.047T .340Odx.078T Nyl . . . . . . . . . . . . . . . . 1
Screw, K40x 20 Pan Hd-Trx Stl Pld Pt Thread Forming . . . . . . . . . . . . . . . . 3
Pistol Plus/Pro Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Potentiometer, C Sltd Sft 1/T .5W 10K Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Anti-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lock, Shaft Pot .250-32 X .125Dia Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Knob, Speed Control 1-10 .140 Shaft X 1.125 Od . . . . . . . . . . . . . . . . . . . . . 1
Screw, Set Stl Sch 8-32 X .187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fitting, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 A/C, 2 W/C
Clamp, Hose .405 − .485 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 A/C, 3 W/C
Hose, Water In 15Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Water In 25Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Water In 35Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Gas In 15Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Gas In 25Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Gas In 35Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conduit/Liner Assembly, 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conduit/Liner Assembly, 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conduit/Liner Assembly, 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Liner,.175−.180 Od X .120 Id Hi Lube 15’ Gun W/Rng . . . . . . . . . . . . . . . . . 1
Liner,.175−.180 Od X .120 Id Hi Lube 25’ Gun W/Rng . . . . . . . . . . . . . . . . . 1
Liner,.175−.180 Od X .120 Id Hi Lube 35’ Gun W/Rng . . . . . . . . . . . . . . . . . 1
Cable, Power/Water Out 15Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power/Water Out 25Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power/Water Out 35Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Control 15Ft - Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Control 25Ft - Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Control 35Ft - Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tubing, Silicone Rbr .500 Id X Spool Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strip, Cop .010 X 1.500 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strain Relief, Cable (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strain Relief, Molded (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Jacket, Cable 2 Ft 4 In (Power Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Cover, Leather W/Velcro 15Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Cover, Leather W/Velcro 25Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Cover, Leather W/Velcro 35Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power 15Ft (Air) - Pistol Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power 25Ft (Air) - Pistol Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power 35Ft (Air) - Pistol Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strip, Copper .010 X 2.000 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, Set 312-18 X .37 Conept Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, Liner Double Wound Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Water Out 10 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 . . . . . . . . . . . . . . . 1 A/C, 2 W/C
Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Guide, Collet Outlet .030-1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Guide, Cone Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, 1−Ear Type Nom Dim .391 X .236 Wide Special . . . . . . . . . . . . . . . . 2
OM-254 824 Page 25
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 9-1. Exploded View Of XR - Pistol - Pro Gun (Continued)
. . 42 . . . . . . . . . . . . 255 716 . . Kit, Head Tube Assy (Air) AP/PP 180Deg 4In. . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . 255 717 . . Kit, Head Tube Assy (Water) AP/PP 180Deg 4In. . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . 248 329 . . W/C Pistol Block Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . 248 388 . . A/C Pistol Block Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . . M1154 . . Screw, 008-32 X .625 Soc Hd-Hex Stl Pld Lkg Patch . . . . . . . . . . . . . . . . . . 2
. . 45 . . . . . . . . . . . . 227 434 . . Drive Roll Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 46 . . . . . . . . . . . . 226 588 . . Screw, 010-32 X .37 Btn Hd-Soc Sst Lkg Patch . . . . . . . . . . . . . . . . . . . . . . . 1
. . 47 . . . . . . . . . . . . 248 466 . . Screw, 18-8 Hex Socket Shld 6-32 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . . 155 565 . . Screw, Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 134 799 . . O-ring, .176 Id X .070 Cs (Used W/Thumbscrew) . . . . . . . . . . . . . . . . . . . . . 1
. . 49 . . . . . . . . . . . . 134 624 . . Washer Shldr .141 Id 0.187 Od X .094T .375 Od X .031T Nyl . . . . . . . . . . . 2
. . 50 . . . . . . . . . . . . 227 435 . . Arm, Pressure (Machined) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 51 . . . . . . . . . . . . 231 443 . . Screw, 006-32 X .44 Soc Hd-Hex Grd 8 Pld Lkg Patch . . . . . . . . . . . . . . . . . 1
. . 52 . . . . . . . . . . . . 227 439 . . Drive Roll Assy, Idler .645 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 53 . . . . . . . . . . . . 227 421 . . Spring, Crspn .360 Od X .059 Wire X .440 Free . . . . . . . . . . . . . . . . . . . . . . . 1
. . 54 . . . . . . . . . . . . 229 850 . . Washer, Pressure Arm Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 55 . . . . . . . . . . . . . M1376 . . Knob, Tension Pistol Pro/Plus 8-32 Thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 56 . . . . . . . . . . . . 229 851 . . Nut, Pressure Arm Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 57 . . . . . . . . . . . . 005 464 . . Screw, Set 250−20x .37 Ovl Pt Sch Stl Pln Nylok . . . . . . . . . . . . . . . . . . . . . 1
. . 58 . . . . . . . . . . . . 235 753 . . Ftg, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 59 . . . . . . . . . . . . 234 971 . . Screw, Set 250−20x .31 Conept Sch Stl W/Nyl Patch (Air) . . . . . . . . . . . . . . 1
. . 59 . . . . . . . . . . . . 078 753 . . Screw, Set 250−20x .31 Cup Pt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 60 . . . . . . . . . . . . 136 679 . . Clamp, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 61 . . . . . . . . . . . . 129 351 . . Screw, 008-32 X .50 Hexwhd .34D W/Spl Gndrng Stl Pld . . . . . . . . . . . . . . . 1
. . 62 . . . . . . . . . . . . 191 121 . . Screw, 006-32 X .37 Btn Hd-Soc Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 63 . . . . . . . . . . . . 164 592 . . Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 64 . . . . . . . . . . . . . M1223 . . Motor Assembly - Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 65 . . . . . . . . . . . . . M1358 . . Lever, Arm Assy Pistol Plus/Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 66 . . . . . . . . . . . . . M1124 . . Set Screw 6-32 X .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 67 . . . . . . . . . . . . 248 328 . . Motor Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 68 . . . . . . . . . . . . . M1106 . . Pistol Plus Manifold Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 69 . . . . . . . . . . . . 227 429 . . Screw, 004-40 X .25 Rnd Hd-Phl Stl Pld Lkkg Patch . . . . . . . . . . . . . . . . . . . 3
. . 70 . . . . . . . . . . . . 089 120 . . Clamp, Hose .375 - .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . . . . M1415 . . Kit, Manifold Block−Air Pistol Pro/Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . . . . M1452 . . Kit, Manifold Block−Water Pistol Pro/Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
OM-254 824 Page 26
. Hardware is common and
5
not available unless listed.
4
3
9
2
8 7
7
1
6
10
T0030
Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Pro Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Pro Gun
(Figure 9-1 Item 42)
. . . . . . . . . . . . . . . . 255 717
. . . 1 . . . . . . . . . . 198 855
. . . 2 . . . . . . . . . . 206 189
. . . 3 . . . . . . . . . . 229 670
. . . 4 . . . . . . . . . . 232 284
. . . 5 . . . . . . . . . . . M1369
. . . 6 . . . . . . . . . . 229 889
. . . 7 . . . . . . . . . . 194 261
. . . 8 . . . . . . . . . . 210 771
. . . 9 . . . . . . . . . . 191 191
. . . 10 . . . . . . . . . . . M1273
. . . . . . . . . . . . . . . . 230 970
..
..
..
..
..
..
..
..
..
..
..
..
Kit, Head Tube Assy (Water) AP/PP 180deg 4in. . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Copper 5/8in. Orifice Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .312 Od .052 And 3/64Al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diffuser, .281/.312 Od Collar Fastip 1/8 Rec Aluma . . . . . . . . . . . . . . . . . . . . . .
Insulator, Nozzle Collared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacket Outer Insulating W/C Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Head Tube Rotation Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, .551 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, 14.99mm Id X 1.27mm Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . .
O−Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Teflon .047−.062 Wire Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Replacement O-Rings Head Tube Water . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
3
1
2
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-254 824 Page 27
. Hardware is common and
not available unless listed.
5
4
3
7
2
1
6
8
T0029
Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Pro Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Pro Gun
(Figure 9-1 Item 42)
. . . . . . . . . . . . . . . . 255 716
. . . 1 . . . . . . . . . . 198 855
. . . 2 . . . . . . . . . . 206 189
. . . 3 . . . . . . . . . . 229 670
. . . 4 . . . . . . . . . . 232 284
. . . 5 . . . . . . . . . . . M1366
. . . 6 . . . . . . . . . . 227 168
. . . 7 . . . . . . . . . . 191 191
. . . 8 . . . . . . . . . . . M1273
. . . . . . . . . . . . . . . . 230 969
..
..
..
..
..
..
..
..
..
..
Kit, Head Tube Assy (Air) AP/PP 180deg 4in. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Copper 5/8in. Orifice Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .312 Od .052 And 3/64Al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diffuser, .281/.312 Od Collar Fastip 1/8 Rec Aluma . . . . . . . . . . . . . . . . . . . . . .
Insulator, Nozzle Collared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacket Outer Insulating A/C Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Head Tube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Teflon .047−.062 Wire Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Replacement O-Rings Head Tube Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
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-254 824 Page 28
Notes
OM-254 824 Page 29
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES
Item
Number
1
2
3
4
5
A/C OUTER
1805
(M1366)
.030−1/16” WIRE
(230 679)
W/C OUTER
1805
4.0” STRAIGHT A/C
(255 716)
(M1369)
(229 670)
COLLARED
INSULATOR
4.0” STRAIGHT W/C
(255 717)
(230 678)
(232 284)
Ref. T0031
Figure 10-1. Consumables Flowchart
Item
No.
Part
No.
Description
Quantity
Consumables Flowchart
Table 10-1. Nozzles
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
1
1
1
1
1
1
1
. . . . . . . . ♦199 610
. . . . . . . . ♦199 611
. . . . . . . . ♦199 612
. . . . . . . . ♦199 613
. . . . . . . . ♦199 614
. . . . . . . . ♦199 615
. . . . . . . . ♦199 616
. . . . . . . . ♦199 617
. . . . . . . . . . 198 855
. . . . . . . . . . 199 618
. . . . . . . . ♦207 313
. . . . . . . . ♦209 035
Nozzle, Screw On Brass 1/2 In. Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Brass 3/4 In. Orifice Straight . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Brass 3/4 In. Orifice Straight Heavy Duty . . . . . . . . . . . . . . 1
Nozzle, Screw On Brass 5/8 In. Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Brass 5/8 In. Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 1/2 In. Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 3/4 In. Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 3/4 In. Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 5/8 In. Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 5/8 In. Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 5/8 In. Orifice 15/16 OD . . . . . . . . . . . . . . . . . . . . . . 1
Nozzle, Screw On Copper 3/8 In. Orifice Tapered (Requires Diffuser 229 670,
230 678 Or 230 679, Used With Any Tapered FasTipt Contact Tip) . . . . . . . 1
. . . 1 . . . . . . . . ♦209 036 . . Nozzle, Screw On Copper 1/2 In. Orifice Tapered (Requires Diffuser 229 670,
230 678 Or 230 679, Used With Any Tapered FasTipt Contact Tip) . . . . . . . 1
OM-254 824 Page 30
..
..
..
..
..
..
..
..
..
..
..
..
Item
No.
Part
No.
Description
Quantity
Consumables Flowchart (Continued)
Table 10-2. Heavy Duty FasTipt Contact Tips*
...
...
...
...
...
...
...
2
2
2
2
2
2
2
. . . . . . . . ♦206 185
. . . . . . . . ♦206 186
. . . . . . . . ♦206 187
. . . . . . . . . . 206 188
. . . . . . . . ♦206 189
. . . . . . . . . . 206 190
. . . . . . . . ♦206 191
..
..
..
..
..
..
..
.030 in. (0.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.035 in. (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.040 in. (1.0 mm) or .035 in (0.9 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . .
.045 in. (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.052 in. (1.3 mm) or 3/64 in (1.2 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . .
1/16 in. (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.068 in. (1.7 mm) or 1/16 in (1.6 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
Table 10-2. Tapered FasTipt Contact Tips*
...
...
...
...
...
...
2
2
2
2
2
2
.........
.........
.........
.........
.........
.........
♦209025
♦209026
♦209027
♦209028
♦209029
♦209030
..
..
..
..
..
..
.030 in. (0.8 mm)
.035 in. (0.9 mm)
.045 in. (1.2 mm)
3/64 in. (1.2 mm)
.052 in. (1.3 mm)
1/16 in. (1.6 mm)
...................................................
...................................................
...................................................
...................................................
...................................................
...................................................
1
1
1
1
1
1
Table 10-3. Gas Diffusers
. . . 3 . . . . . . . . . . 229 670 . . 1/8 in. Tip Recess − For Heavy Duty FasTip Contact Tips
(Standard On All Guns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . ♦230 678 . . 1/4 in. Tip Recess − For Heavy Duty FasTip Contact Tips . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . ♦230 679 . . Flush Tip − For Heavy Duty FasTip Contact Tips . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-4. Insulators
. . . 4 . . . . . . . . . . . M1366 . . Insulator, Head Tubes Aluma/Pistol Pro A/C 4 In. . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . M1369 . . Insulator, Head Tubes Aluma/Pistol Pro W/C 4 In. . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 232 284 . . Insulator, Nozzle Collared Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-5. Head Tube Assemblies
. . . 5 . . . . . . . . . . 255 716 . . Kit, Head Tube Assy (A) AP/PP 180Deg 4In. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 255 717 . . Kit, Head Tube Assy (W) AP/PP 180Deg 4In. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-6. Head Tube Liners (Not Shown)
. . . . . . . . . . . . . . . . . M1272 . . Liner, Teflon .030−.035 Wire Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . M1273 . . Liner, Teflon .047−.062 Wire Pistol Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Wire Kit (Not Shown)
. . . . . . . . . . . . . . ♦230 708 . . Kit, Idler Roll 1/16 (.062) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . ♦198 377 . . Hardwire Liner Kit, 30W For Steel&Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-254 824 Page 31
Notes
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
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.
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, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
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 one year after
the equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* 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
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
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.)
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.
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 2013-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
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
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2013 Miller Electric Mfg. Co.
2013−01
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising