Miller | MF220315T | Owner Manual | Miller XR ALUMA-PRO LITE (AIR-COOLED GUN) User manual

Miller XR ALUMA-PRO LITE (AIR-COOLED GUN) User manual
OM-254 286E
2015−04
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air-Cooled,
MIG (GMAW) Welding Gun
™
XR-A Aluma-Pro Lite
(Air-Cooled Gun)
175 Ampere (Air) Push-Pull Welding Gun
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.
1-2.
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1-3.
1-4.
Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE
2
2-1.
AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
2-2.
2-3.
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
2-4.
Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-5.
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
3-2. Miscellaneous Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
4-1.
4-2.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or
Constant Current/Constant Voltage (CC/CV) Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . .
9
5-2.
5-3.
9
Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P/Millermatic 252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
5-5.
5-6.
Threading Welding Wire Through XR-Control Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
5-7.
5-8.
Opening Top Cover Of XR Aluma-Pro Lite Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
5-4.
11
12
6-2.
6-3.
Gun Pressure Roll Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
6-4.
6-5.
Gun Drive Assembly Maintenance For An XR Aluma-Pro Lite Gun . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Head Tube Liner In XR Aluma-Pro Lite Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
6-6.
6-7.
Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing The Gun Liner On XR Aluma-Pro Lite Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
7-2. Cleaning The Gun Liner On XR Aluma-Pro Lite Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
23
SECTION 9- PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10- PARTS LIST OF CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
28
WARRANTY
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2013-09
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 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.
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.
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-254 286 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.
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.
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.)
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). 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 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:
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.
OM-254 286 Page 2
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.
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
3
SR7(MIG)_2013−09 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
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 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 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.
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.
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.
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.
OM-254 286 Page 3
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.
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.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Éloigner les mains et le corps de la buse du
pistolet après avoir appuyé sur la gâchette.
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.
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.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D Vérifier si les niveaux de bruit excèdent les limites spécifiées par l’OSHA.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
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. 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. 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
OM-254 286 Page 4
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.
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.
OM-254 286 Page 5
OM-254 286 Page 6
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
Drive rolls can injure fingers.
Safe32 2012−05
3-2. Miscellaneous Symbols
A
U1
Amperes
Primary Voltage
V
U2
Volts
Load Voltage
Output
I1
Primary Current
X
I2
Duty Cycle
Rated Welding
Current
Notes
OM-254 286 Page 7
SECTION 4 − INTRODUCTION
4-1. Specifications
Model
XR-A Aluma-Pro Lite 25 Ft
Welding Output Range
175 A at 60% Duty Cycle
Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
.035 − 3/64 in
(0.9 − 1.2 mm)
70 − 900 IPM
(1.8 − 23.0 mpm)
2.1 lb (1.0 kg)
(less cables)
(Torch Only)
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.
60% Duty Cycle At 175 Peak Amperage
60%dutycycle
6 Minutes Welding
4 Minutes Resting
sduty1 5/95
Notes
OM-254 286 Page 8
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 Current (CC), Constant Voltage (CV) Or
Constant Current/Constant Voltage (CC/CV) Welding Power Source
9
1
7
2
8
6
3
9
5
XR-D
4
1
5
Millermatic 350P
Ref. 257 513-A / Ref. 257 512-A
1
2
3
CC, CV Or CC/CV Welding Power
Source
24 VAC/Contactor Control 14-Pin
Plug
Negative (−) Weld Cable
4
Workpiece
8
Positive (+) Weld Cable
5
Welding Gun
9
Gas Cylinder
6
Wire Feeder
7
24 VAC/Contactor Control Cord
. Shielding gas pressure not to exceed
100 psi (689 kPa).
OM-254 286 Page 9
5-2. Gun Connections
4
5
Left Side
3
2
1
Ref. 257 513-A
1 Gun Control Cable
Insert plug into Gun Control receptacle, and
tighten threaded collar.
2 Gun Power Pin
OM-254 286 Page 10
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. Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P/Millermatic 252
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.
. The Millermatic 252 is only a
two drive roll system.
Tools Needed:
1
2
3
4
5
8
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 5-8 for threading welding
wire through XR Aluma-Pro Lite gun.
Section 5.3
OM-254 286 Page 11
5-4. Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P Aluminum
1
2
3
4
5
6
7
8
8
6
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Wire Conduit
Pressure Adjustment Knob
Gun Conduit Cable
Jog/Purge Switch
Lay gun cable out straight.
Tools Needed:
1
2
3
7
5
4
.
Hold wire tightly to keep
it from unraveling.
6 in.
(150 mm)
Open pressure assembly.
Install proper size drive rolls.
Pull and hold wire; cut off end.
Push wire thru inlet guide, along
drive roll groove, and into wire
conduit; continue to hold wire.
Tension Settings
Wire Size
Setting
0.035 in.
1−2
0.040 in.
3/64 in.
3−4
Close and tighten pressure
assembly according to Tension
Setting chart, and let go of wire.
Turn On.
Remove gun nozzle and contact tip.
Press gun trigger or jog switch until wire comes
out of gun. Reinstall contact tip and nozzle.
Close and latch door on power source.
255 204-B / Ref. 242 439-A / 257 466-A / 257 470-A
OM-254 286 Page 12
5-5. Threading Welding Wire Through XR-Control Feeder
1
Cable Assembly
Lay cable assembly out straight.
2
2
Jog Switch
Push Jog switch up to feed wire through
cable assembly.
3
3
Torque Switch
. Select proper push feeder torque setting 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 autoJOG / PURGE
matically set internally for wire sizes.
1
Adjusting Tension At Feeder
1
. Hold wire tightly to keep
1
it from unraveling.
1
Tension Arm
6 in.
(150 mm)
Pull and hold wire; cut off end.
Open tension arm.
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
0.035 in.
Welding
1−2
0.040 in.
3/64 in.
Gun Calibration
3−4
3−4
Tools Needed:
Section 5.4 / Ref. 805 350-A / 242 517-A
OM-254 286 Page 13
5-6. 10-Pin Plug Information
10
E
D
F
J
G
I
C
H
B
A
Pin*
Pin Information
A
Not used
B
Motor Common
G
Trigger
C
Motor 0 to +24 volts DC with respect to pin B
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
5-7. Opening Top Cover Of XR Aluma-Pro Lite Gun
1
Top Cover
Squeeze sides of cover and lift up
as shown.
To close cover, pivot cover closed
on gun, and push cover down until
cover locks tight.
1
257 516-A / 257 517-A
OM-254 286 Page 14
5-8. Threading Welding Wire Through Gun
. Refer to Section 5-3 for instructions on feeding
wire through feeder.
For XR Aluma-Pro Lite Gun:
!
Welding wire is electrically live when
gun trigger is used to jog wire.
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.
Cut off wire. Close and
latch wire feeder door.
Tools Needed:
257 518-A / 257 516-A / 257 519-A
OM-254 286 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.
Switches inside 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
Gun Wire Speed Control
Use control to fine adjust wire feed
speed set on XR-Control. Gun Wire
Speed Control has 3-3/4 turns of adjustment from minimum to maximum.
2
1
Rotate control clockwise to increase
wire speed and counterclockwise to
decrease wire speed.
. Speed
control can be rotated
more than 3-3/4 turns in both directions without being damaged.
257 489-A
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
Pressure Roll Adjustment
Screw
Wire tension should be set to 4XXX
for 4000 series aluminum wire.
1
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.
Tools Needed:
257 516-A / 257 519-A
OM-254 286 Page 16
6-3. Shielding Gas
1
2
3
Shielding Gas Cylinder
Valve
Gun Trigger
Open valve on cylinder just before
welding.
2
Gun trigger turns weld output and
gas flow on and off (see Section
6-1).
1
Close valve on cylinder when
finished welding.
3
257 520-A
6-4. Gun Drive Assembly Maintenance For An XR Aluma-Pro Lite Gun
1
Lever Arm
Using lever arm open pressure roll
with bearing as shown.
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.
2
3
Pressure Roll
Thread welding wire through gun.
Close pressure roll assembly and
idler roll (located in XR control box).
Press jog switch until wire is sticking
out end of contact tip.
. When changing
wire size you
should change the drive rolls in
the XR control box or Millermatic.
See XR or Millermatic Owner’s
Manual for details.
Close top cover.
1
3
Tools Needed:
7/64, 1/16 in.
3/8 in.
257 523-A
OM-254 286 Page 17
6-5. Replacing Head Tube Liner In XR Aluma-Pro Lite Gun
The standard head tube liner
(yellow) will accommodate 3/64 in.
wire size.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized
liner.
1
2
Head Tube
Head Tube Nut
Loosen head tube nut and remove
head tube from gun.
3
3
Head Tube Liner
Pull liner out of head tube.
Insert new liner into head tube and
reinstall head tube onto gun.
2
.A
twisting motion may be
needed to feed liner thru head
tube.
1
NOTICE − Be sure head tube is
seated and head tube nut is securely
tightened before operating gun. If
head tube nut is not adequately
tightened, unwanted arcing may
occur between head tube and gun
housing.
257 474-A
6-6. Changing Gun Contact Tip
Remove nozzle
1
Nozzle
2
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 7-3).
Reinstall nozzle.
1
2
257 478-A
OM-254 286 Page 18
6-7. Replacing The Gun Liner On XR Aluma-Pro Lite Gun
1
. Refer To Instructions Below.
3
2
Power Pin End
1
257 472-B
!
Turn Off welding power source and
wire feeder.
Remove the gun from the power supply.
Remove the liner setscrew in the head of
the gun.
1
Liner Guide Nut
2
Liner
Loosen the liner guide nut from power pin
end of gun.
3
Power Pin
Remove used liner.
Lay gun cable out straight and remove wire
from the gun.
Slide new liner as close as possible to gun
drive rolls without touching.
Gently tighten setscrew in gun handle until
you can feel setscrew contacting liner, then
tighten another 1/2 turn.
NOTICE − Overtightening setscrew may
cause damage to new liner.
Tighten liner guide nut. Liner guide nut will
hold liner securely in place. Cut off liner
leaving 1/4 in. sticking out from liner guide.
OM-254 286 Page 19
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
n = Check
~ = Clean
l = Replace
Daily
n~ Head Tube Liner and
Drive Casting
(see Section 6-5)
Weekly
n~ Drive Roll
Every
Spool
of Wire
Or
n~ Nozzle / Contact Tip
~ Gun Casing
n~ Gun Liner
(see Section 7-2)
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
n 10-Pin Cord
n Gas Hose and Fittings
n Gun Cable
Every
3
Months
OM-254 286 Page 20
7-2. Cleaning The Gun Liner On XR Aluma-Pro Lite Gun
!
Turn Off welding power
source and wire feeder.
Lay gun cable out straight.
1
Top Cover
Open top cover and turn gun upside down.
2
3
Air Nozzle
Power Pin
Blow air from power pin end
through liner until clean of debris. Verify drive assembly is
clear of debris.
1
2
3
Power Pin End
257 473-A
OM-254 286 Page 21
7-3. Troubleshooting Table
!
Disconnect power before troubleshooting.
Trouble
Remedy
No wire feed at gun, feeder not operat- Reset circuit breaker in feeder/control box. See feeder/control owner’s manual.
ing. Check motor or brake solenoid.
Replace trigger-switch and test operation.
Check trigger-switch wires for continuity.
No wire feed at gun, feeder operating Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s
manual.
properly.
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.
Check operation of welding power source.
Wire feeds erratically.
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).
Wire feeds one speed only.
Check potentiometer with meter and replace if necessary.
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 Secure plug from gun control cable into gun control receptacle on feeder.
feeder. Welding wire is not energized.
Shielding gas does not flow.
Wire feeds, shielding gas flows, but See Troubleshooting section in welding power source manual.
welding wire is not energized.
Arc varies and welding wire is kinked Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire on
when feeding out gun.
an XR control box.
OM-254 286 Page 22
SECTION 8 − ELECTRICAL DIAGRAMS
254 289-A
Figure 8-1. Circuit Diagram For XR Aluma-Pro Lite Gun
Notes
OM-254 826 Page 23
SECTION 9- PARTS LIST
. Hardware is common and
not available unless listed.
2
3
4
5
1
30
8
9
10
Figure 9-1. Exploded View Of XR Aluma-Pro Lite Gun
OM-254 286 Page 24
7
6
11
12
14
13
15
16
19
17
23
20
13
22
18
20
20
25
26
27
28
29
28
21
24
T0044-A
OM-254 286 Page 25
Item
No.
Part
No.
Description
Quantity
Figure 9-1. Exploded View Of XR Aluma-Pro Lite Gun
. . . 1 . . . . . . See Fig. 9-2
. . . 2 . . . . . . . . . +254620
. . . . . . . . . . . . . . . . 187316
. . . 3 . . . . . . . . . . 258060
. . . 4 . . . . . . . . . . 217934
. . . 5 . . . . . . . . . ♦258541
. . . 5 . . . . . . . . . ♦258542
. . . 5 . . . . . . . . . ♦258726
. . . 5 . . . . . . . . . ♦258727
. . . 6 . . . . . . . . . . 254788
. . . 7 . . . . . . . . . . 254786
. . . 8 . . . . . . . . . . 254789
. . . 9 . . . . . . . . . . 254476
. . . 10 . . . . . . . . . . 254690
. . . 11 . . . . . . . . . . 242638
. . . 12 . . . . . . . . . . 254701
. . . 13 . . . . . . . . . . 254760
. . . 14 . . . . . . . . . . 254698
. . . 15 . . . . . . . . . . 254782
. . . 16 . . . . . . . . . . 254781
. . . 17 . . . . . . . . . . 254657
. . . 18 . . . . . . . . . . 254784
. . . 19 . . . . . . . . . . 258192
. . . 20 . . . . . . . . . . 254705
. . . 21 . . . . . . . . . . 254647
. . . 22 . . . . . . . . . . 254787
. . . 23 . . . . . . . . . . 135126
. . . 24 . . . . . . . . . . 258190
. . . 25 . . . . . . . . . . 254756
. . . 26 . . . . . . . . . . 254715
. . . 27 . . . . . . . . . . 231443
. . . 28 . . . . . . . . . . 134624
. . . 29 . . . . . . . . . . 227439
. . . 30 . . . . . . . . . . . M1440
. . Head Tube Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Pinch Wordless WF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle Assy, Left/Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, K40 x 20 Pan Hd−Trx Stl Pld Pt Thread Forming . . . . . . . . . . . .
. . Kit, Jump Liner Assy .030−.035 (5 pk) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Jump Liner Assy .047−.062 (5 pk) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Jump Liner Assy .030−.035 14 in. Long (5 pk) . . . . . . . . . . . . . . . . .
. . Kit Jump Liner Assy .047−.062 14 in. Long (5 pk) . . . . . . . . . . . . . . . . . .
. . Guide, Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Wire Guide Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief, Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Combination 25 ft w/Power Connector . . . . . . . . . . . . . . . . . . . . .
. . Strip, Cop .010 x 1.000 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 006−32 x .25 Pan Hd−Phl Stl Pld Lkg Patch . . . . . . . . . . . . . . . .
. . Clamp, Cable Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 008−32 x .31 Soc Hd Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Torch Body, Brazed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Dowel Stl .094 Dia x 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spring, Cprsn .250 OD x .026 Wire x .625 Free St . . . . . . . . . . . . . . . .
. . Paddle, Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set #10−24 x .25 Ovlpt Stl Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Motor Assy, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 006−32 x .31 Soc Hd Cap w/Nylon Patch . . . . . . . . . . . . . . . . . .
. . Potentiometer & Switch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Wire Guide Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set # 6−32 x .12 Cup Pt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . .
. . Wire Drive Assy, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Roll, Drive Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Contact, Current Pick−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 006−32 x .44 Soc Hd−Hex Gr8 Pld Lkg Patch . . . . . . . . . . . . . .
. . Washer, Shldr.140id 0.187 OD x.094T .375 OD x.031T Nyl . . . . . . . . .
. . Drive Roll Assy, Idler .645 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Liner Kits 258726 and 258727 are for use with optional Bernard Head Tubes, and must be cut to fit.
1
1
1
1
7
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
7
1
1
1
1
1
1
1
2
1
1
♦OPTIONAL
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number are required when ordering parts from your local distributor.
OM-254 286 Page 26
. Hardware is common and
not available unless listed.
6
1
2
3
5
4
257 872-A
Figure 9-2. Head Tube Assembly Of XR Aluma-Pro Lite Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-2. Head Tube Assembly Of XR Aluma-Pro Lite Gun
(Figure 9-1 Item 1)
. . . . . . . . . . . . . . . . . 254477 . . . . Head Tube Assy, Aluma Pro Lite (Including) . . . . . . . . . . . . . . . . . . . . . . . . .
. . 1 . . . . . . . . . . . . QT2−45 . . . . . . Tube, Body 45 Degree x 2.69 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 1840057 . . . . . Clip-on Q-Nut Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 1840031 . . . . . Body Tube Insulating Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2 . . . . . . . . . . . . 4323R . . . . . . . Insulator, Nozzle (Small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . DS−1 . . . . . . . . Diffuser, C−Fire (Small Nozzle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . NS−1218C . . . Nozzle, C−Fire Small Copper 1/2 in. Recess 1/8 in. . . . . . . . . . . . . . . . . .
. . 5 . . . . . . . . . . . . T−047AL . . . . Centerfire Contact Tip, Aluminum 3/64 in. . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5 . . . . . . . . ♦ . T−035AL . . . . . Centerfire Contact Tip, Aluminum .035 in. . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . ♦ . 258541 . . . . Kit, Jump Liner Assy .030−.035 (5 pk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . ♦ . 258542 . . . . Kit, Jump Liner Assy .047−.062 (5 pk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . ♦ . 258726 . . . . Kit, Jump Liner Assy .030−.035 14 in. Long (5 pk) . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . ♦ . 258727 . . . . Kit Jump Liner Assy .047−.062 14 in. Long (5 pk) . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
2
1
1
1
1
. Liner Kits 258726 and 258727 are for use with optional Bernard Head Tubes, and must be cut to fit.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number are required when ordering parts from your local distributor.
OM-254 286 Page 27
SECTION 10- PARTS LIST OF CONSUMABLES
Standard Centerfiret Series Consumables
T Series Contact Tips For Aluminum Wire
Gas Diffusers
Large Nozzles
T−035AL* .035 in. (0.9 mm)
DS−1AP* Small
N−3414C
T−047AL* .047 in. (1.2 mm)
D−1AP Large
Copper, 3/4 in. I.D., 1/4 in. tip recess
N−3418B
Small Nozzles
Brass, 3/4 in. I.D., 1/8 in. tip recess
NS−5818B
N−3414B
T−030 .030 in. (0.8 mm)
Brass, 5/8 in. I.D., 1/8 in. tip recess
Brass, 3/4 in. I.D., 1/4 in. tip recess
T−035 .035 in. (0.9 mm)
NS−1218B
N−3414C
T−039 .039 in. (1.0 mm)
Brass, 1/2 in. I.D., 1/8 in. tip recess
Copper, 5/8 in. I.D., 1/4 in. tip recess
T−045 .045 in. (1.2 mm)
NS−1218C*
N−5818B
TT Series Contact Tips For Hard Or
Cored Wires 2 in. (51 mm)
Copper, 1/2 in. I.D., 1/8 in. tip recess
Brass, 5/8 in. I.D., 1/8 in. tip recess
TT−030 .030 in. (0.8 mm)
NS−1200B
N−5814B
TT−035 .035 in. (0.9 mm)
Brass, 1/2 in. I.D., flush tip
Brass, 5/8 in. I.D., 1/4 in. tip recess
TT−045 .045 in. (1.2 mm)
NST−3818B
T Series Contact Tips For Hard Or
Cored Wires 1.5 in. (38 mm)
Brass, 3/8 in. I.D., 1/8 in. tip recess
*Comes standard with XR Aluma-Pro Lite.
T Series Tip
5/8-inch I.D.
T-035AL/T-047AL
Standard
1/2-inch I.D.
3/4-inch I.D.
NS-1218C Standard
Diffuser
3/8-inch I.D.
Tapered Tip
DS-1AP Standard
TT Series Tip
Small Nozzle
Small Nozzle (and Standard) Configurations
Diffuser
T Series Tip
5/8-inch I.D.
D-1AP
Large Nozzle
Large Nozzle Configurations
Ref. M/1.75 2012−02
Figure 10-1. Standard Centerfiret Series Consumables Flowchart
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number are required when ordering parts from your local distributor.
OM-254 286 Page 28
Optional FasTipt Consumables
. The use of FasTip Consumables requires the use of long head tube liners. Order long head tube liners from the standard replacement
consumables in Table 10-6.
1
Item
Number
2
3
(#206 196)
.030−1/16”
(#206 195)
(#210 664)
Figure 10-2. Optional FasTipt Consumables Flowchart
Item
No.
Part
No.
Description
Quantity
Figure 10-2. Optional FasTipt Consumables Flowchart
Table 10-1. Screw-On Brass Nozzles
Item
No.
...
...
...
...
...
1
1
1
1
1
........
........
........
........
........
Part
No.
♦199 610
♦199 611
♦199 612
♦199 613
♦199 614
Description
..
..
..
..
..
Quantity
Nozzle, Screw On Brass 1/2 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Brass 3/4 in Orifice Straight . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Brass 3/4 in Orifice Straight Heavy Duty . . . . . . . . . . . . . . .
Nozzle, Screw On Brass 5/8 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Brass 5/8 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number are required when ordering parts from your local distributor.
OM-254 286 Page 29
Table 10-2. Screw-On Copper Nozzles
Item
No.
...
...
...
...
...
...
...
1
1
1
1
1
1
1
........
........
........
........
........
........
........
Part
No.
♦199 615
♦199 616
♦199 617
♦198 855
♦199 618
♦207 313
♦209 035
Description
Quantity
..
..
..
..
..
..
..
Nozzle, Screw On Copper 1/2 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 3/4 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 3/4 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 5/8 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 5/8 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 5/8 in Orifice 15/16 OD . . . . . . . . . . . . . . . . . . . . . . .
Nozzle, Screw On Copper 3/8 in Orifice Tapered (Requires Diffuser 229 670,
230 678, 230 679 Used With Any Tapered FasTipt Contact Tip) . . . . . . . . . .
. . . 1 . . . . . . . . ♦209 036 . . Nozzle, Screw On Copper 1/2 in Orifice Tapered (Requires Diffuser 229 670,
230 678, 230 679 Used With Any Tapered FasTipt Contact Tip) . . . . . . . . . .
1
1
1
1
1
1
1
1
Table 10-3. Heavy Duty FasTiptContact Tips*
Item
No.
...
...
...
...
...
2
2
2
2
2
........
........
........
........
........
Part
No.
♦206 186
♦206 187
♦206 188
♦206 189
♦206 191
Description
..
..
..
..
..
Quantity
.030 in (0.8 mm) Aluminum Wire
.035 in (0.9 mm) Aluminum Wire
.040 in (1.0 mm) Aluminum Wire
3/64 in (1.2 mm) Aluminum Wire
1/16 in (1.6 mm) Aluminum Wire
......................................
......................................
......................................
......................................
......................................
1
1
1
1
1
Table 10-4. Tapered FasTipt Contact Tips*
Item
No.
...
...
...
...
...
...
2
2
2
2
2
2
........
........
........
........
........
........
Part
No.
♦209 025
♦209 026
♦209 027
♦209 028
♦209 029
♦209 030
Description
..
..
..
..
..
..
.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)
Quantity
....................................................
....................................................
....................................................
....................................................
....................................................
....................................................
1
1
1
1
1
1
Table 10-5. Tapered FasTipt Contact Tips*
Item
No.
Part
No.
Description
Quantity
. . . 3 . . . . . . . . ♦206 195 . . Diffuser, .281/.312 OD Fastip 1/8 Tip Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . ♦210 664 . . Diffuser, .281/.312 OD Fastip 1/4 Tip Recess . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . ♦206 196 . . Diffuser, .281/.312 OD Fastip Flush Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-6. Standard Replacement Consumables
Aluminum
Wire Size
Drive Rolls
Idler Rolls
Inlet Guides
.030 in. (0.8 mm)
254 756
227 439
227 408
.035 in. (0.9 mm)
254 756
227 439
227 408
.040 in. (1.0 mm)
254 756
227 439
227 408
3/64 in. (1.2 mm)
254 756
227 439
227 408
Head Tube Liner:
Standard Barrel
With Centerfire
Consumables (5 pk)
Long Head Tube Liner:
Optional Barrels Or FasTip
Consumables (5 pk)
258 541
(.030 and .035 in. Wire)
258 726
258 542
(.040 and 3/64 in. Wire)
258 727
Cable Liner
25 ft (7.6 m)
258 726
M1440
258 727
♦OPTIONAL
*All contact tips are packaged in bags of 25.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number are required when ordering parts from your local distributor.
OM-254 286 Page 30
Effective January 1, 2015
(Equipment with a serial number preface of MF 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
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
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.
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 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
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* 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.)
* LiveArc Welding Performance Management System
* 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
* 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 2015-01
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
© 2015 Miller Electric Mfg. Co.
2015−01
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