Miller | MB090002T | Owner Manual | Miller XR-ALUMAPRO CE User manual

Miller XR-ALUMAPRO CE User manual
OM-248 984A
2011−01
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air/WaterCooled, MIG (GMAW) Welding
Gun
™
XR - AlumaPro
(Air And Water-Cooled Guns)
CE
250 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) 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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant
Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle . . . . . . . . . . . . . . . . . . . . . .
4-2. Air-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Water-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Millermatic 350P Water Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Threading Welding Wire For AlumaPro Gun And Millermatic 350P . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Threading Welding Wire Through XR-Control Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Adjusting Tension At Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. 10-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Opening Top Cover Of XR-AlumaPro Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Gun Pressure Roll Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Coolant Supply For Water-Cooled Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Replacing Head Tube Liner In XR-AlumaPro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Replacing The Gun Liner On XR-AlumaPro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance For Aluminum Push/Pull Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Cleaning The Gun Liner On XR-AlumaPro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST INCLUDING CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
2
2
3
3
3
4
4
4
4
5
5
6
7
8
9
10
11
12
12
13
14
14
14
15
15
16
17
17
18
19
19
20
21
22
24
29
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
XR­A ALUMA­PRO
XR­W ALUMA­PRO
Stock Number
300805, 300806, 300807
300003, 300004, 300265
Council Directives:
• 2006/95/EC Low Voltage
Standards:
• IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
• IEC 60974­7:2005 Arc welding equipment – Part 7: Torches
• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
US Signatory:
December 16, 2010
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
248168A
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2010−03
Protect yourself and others from injury — read and follow these precautions.
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.
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.
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.
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.
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.
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.
WELDING can cause fire or explosion.
D Do not weld near flammable material.
D Do not weld on closed containers.
D Watch for fire; keep extinguisher nearby.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied respirator.
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-248 984 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. 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, access restrictions for passers−by or 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.
3. Do not coil or drape cables around your body.
OM-248 984 Page 2
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 − DEFINITIONS
2-1. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
2-2. Symbols And Definitions
A
IP
Amperes
X
Volts
Alternating Current
Hertz
Circuit Breaker
Wire Feed
Jog
Output
Trigger
Gun
Press To Set
Increase
Trigger Hold On
Trigger Hold Off
Purge
Spot Weld Time
Percent
Run-In
Load Voltage
Read Instructions
Rated Current
Line Connection
Water (Coolant) Input
Fuse
Continuous
Spot Welding
Degree Of
Protection
Burnback Time
I1
V
Hz
Primary Current
Water (Coolant)
Output
U1
I2
Primary Voltage
U2
Duty Cycle
OM-248 984 Page 3
SECTION 3 − INTRODUCTION
3-1. Important Information Regarding CE Products (Sold Within The EU)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
3-2. Specifications
Model
Welding Output Range
Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
(Torch Only)
XR-AlumaPro Gun
(Air Cooled)
250 A at 60% Duty Cycle
with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.5 lb (1.1 kg)
(less cables)
XR-AlumaPro Gun
(Water Cooled)
400 A at 100% Duty Cycle
with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.9 lb (1.3 kg)
(less cables)
. When using 1/16 in (1.6 mm) wire, kit 230708 must be installed.
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Air-Cooled Models
60% Duty Cycle At 250 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding
Water-Cooled Models
100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding
sduty1 5/95
OM-248 984 Page 4
SECTION 4 − 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.
4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant
Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle
9
1
7
2
8
6
3
9
5
XR-D
4
1
5
Ref. 804 653-A / 805 349-A
Millermatic 350P
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-248 984 Page 5
4-2. Air-Cooled Gun Connections
4
5
Left Side
3
2
Ref. 245 995-A / 246 218-A / 151 666-G
1
1 Gun Control Cable
Insert plug into Gun Control receptacle, and
tighten threaded collar.
2 Gun Power Pin
OM-248 984 Page 6
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.
4-3. 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
9
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
Gun Power Pin
Gun Securing Knob
Gun Bushing
Drive Casting
8
9
10
11
Water Cooler Output
Water Cooler Input
Feeder (Coolant) Output
Feeder (Coolant) Input
10
11
4
Tools Needed:
7
9/16 in.
6
2
1
Ref. 245 997-A / 805 353-A / 246 218-A / 151 666-G
OM-248 984 Page 7
4-4. Millermatic 350P Water Cooled Gun Connections
8
7
1
2
Ref. 804 945-A
6
5
3
4
Tools Needed:
9/16 in.
NOTICE − 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-248 984 Page 8
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”
4-5. Threading Welding Wire For AlumaPro Gun And Millermatic 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 4-10 for threading welding wire through AlumaPro guns.
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
OM-248 984 Page 9
4-6. 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-248 984 Page 10
4-7. 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
0.035 in.
Welding
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-248 984 Page 11
4-8. 10-Pin Plug Information
10
E
D
F
J
G
I
C
B
Pin*
H
A
Pin Information
A
Electrode sense lead
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
4-9. Opening Top Cover Of XR-AlumaPro 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
Ref. 804 544-B
OM-248 984 Page 12
4-10. Threading Welding Wire Through Gun
. Refer to Section 4-5 for instructions on feeding
wire through feeder.
For XR-AlumaPro Gun:
!
Welding wire is electrically live when
gun trigger is used to jog wire.
. Turn OFF coolant supply before threading wire
through 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 5-2.
Cut off wire. Close and
latch wire feeder door.
Tools Needed:
Ref. 804 544-B / 804 545-B
OM-248 984 Page 13
SECTION 5 − OPERATION
5-1. 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.
Rotate control clockwise to increase
wire speed and counterclockwise to
decrease wire speed.
1
2
. Speed
control can be rotated
more than 3-3/4 turns in both directions without being damaged.
Ref. 804 545-B
5-2. 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.
Tools Needed:
Rotate Pressure Roll Adjustment
Screw fully clockwise until indicator
line on adjustment knob lines up
with indicator line on handle in the
5XXX position.
Ref. 804 545-B
OM-248 984 Page 14
5-3. 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
5-1).
2
1
Close valve on cylinder when
finished welding.
3
Ref. 151 666-F / 804 545-B
5-4. Coolant Supply For Water-Cooled Models Only
1
2
3
Coolant Supply
Coolant “In”
Coolant “Out”
See table below for coolant
guidelines.
Turn On coolant supply before
welding.
Turn Off coolant supply when
finished welding.
1
3
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
*MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Ref. 150 755-A
OM-248 984 Page 15
5-5. Gun Drive Assembly Maintenance For An XR-AlumaPro 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.
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.
2
. When changing wire size and
using an XR control box you
should change the control box
drive roll and idler. See XR
owners manual for details.
Close top cover.
1
3
Tools Needed:
7/64, 1/16 in.
3/8 in.
Ref. 804 544-B / 805 194-A
OM-248 984 Page 16
5-6. Replacing Head Tube Liner In XR-AlumaPro Guns
. 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.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized liner.
3
1
2
2
Head Tube
Head Tube Nut
Loosen head tube nut and remove
head tube from gun.
3
Head Tube Liner
Pull liner out of head tube.
Insert new liner into head tube (install
tapered end first) and reinstall head
tube onto gun.
1
Tapered end
. A twisting motion may be needed to feed liner thru head tube.
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.
Ref. 804 544-B
5-7. Changing Gun Contact Tip
Remove nozzle
1
Nozzle
2
FasTip
Unscrew FasTip.
Install new FasTip.
NOTICE − Make sure correct size
contact tip is being used. Incorrect
size may cause arcing inside tip,
poor feedability and poor arc starting characteristics(see Section 9).
Reinstall nozzle.
2
1
Ref. 804 709-A
OM-248 984 Page 17
5-8. Replacing The Gun Liner On XR-AlumaPro Guns
1
4
2
3
Gun End
. Refer To Instructions Below.
Remove Old Liner (Item 2) From Gun End
Install New Liner (Item 2) Into Gun End
5
6
7
2
Power Pin End
. Gently pry open
slots to remove
wire collet guide.
. Cut liner flush with
wire collet guide.
Ref. 804 546-A
!
Turn Off welding power source and
wire feeder.
Remove short leather cover to access liner
assembly.
liner is through power pin assembly and is
visible.
1
2
3
4
5
6
7
Leather Cover
Liner
Liner Lock Allen Screw
Liner Guide Reducer
Wire Guide Cone
Wire Collet Guide
Power Pin
Loosen liner lock allen screw (located near
back of handle) to remove liner guide reducer from gun.
Install liner assembly into gun and firmly
tighten (do not over tighten) liner lock allen
screw.
Remove wire guide cone and wire collet
guide from power pin.
Reinstall wire collet guide at power pin and
tighten onto liner.
Remove old liner from gun end (see illustration above).
Cut liner off flush with wire collet guide. Reinstall wire guide cone.
Insert new liner into gun end and continue
feeding liner through cable assembly until
Refer to Owner’s Manual for instructions
on rethreading wire.
Lay gun cable out straight.
OM-248 984 Page 18
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance For Aluminum Push/Pull Guns
!
n = Check
~ = Clean
Disconnect power
before maintaining.
l = Replace
Daily
n~ Head Tube Liner and
Drive Casting
(see Section 5-6)
Weekly
n~ Drive Roll
Every
Spool
of Wire
Or
n~ Nozzle / Contact Tip
~ Gun Casing
n~ Gun Liner
(see Section 6-2)
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
n 14-Pin Cord
n Gas Hose and Fittings
n Gun Cable
Every
3
Months
OM-248 984 Page 19
6-2. Cleaning The Gun Liner On XR-AlumaPro Guns
!
1
2
Turn Off welding power
source and wire feeder.
NOTICE − Clean gun liner before cleaning stainless tube and
inlet guide.
3
Lay gun cable out straight.
1
Leather Cover
Remove leather cover to access liner assembly.
Gun End
2
3
4
5
Liner Guide Reducer
Liner Lock Allen Screw
Power Pin
Air Nozzle
Loosen liner lock allen screw
(located near back of handle) to
remove liner guide reducer from
gun.
Blow air from power pin end
through liner until clean of debris.
5
4
Reinstall liner assembly into
gun and firmly tighten (do not
overtighten) liner lock allen
screw when finished cleaning.
Power Pin End
NOTICE − Do not overtighten
liner lock allen screw.
6
Top Cover
7
Set Screw (Inlet Guide)
8
Inlet Guide
Remove inlet guide. From power pin end, blow air through liner
and stainless tube until free of
debris.
Reinstall inlet guide.
6
7
8
5
4
Power Pin End
OM-248 984 Page 20
Ref. 804 544-B / Ref. 804 546-A
6-3. 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 ener- Clean and tighten all power connections.
gized.
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 5-2).
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.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
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-248 984 Page 21
SECTION 7 − ELECTRICAL DIAGRAMS
228 669-B
Figure 7-1. Circuit Diagram For XR-AlumaPro Gun
Notes
OM-248 984 Page 22
Notes
OM-248 984 Page 23
SECTION 8 − PARTS LIST
. Hardware is common and
3
not available unless listed.
4
2
1
34
33
38
49
35
37
44
22
39
48
40
35
10
49
45
41
17
46
43
21
18
42
47
23
14
Figure 8-1. Exploded View Of XR-A AlumaPro Gun
OM-248 984 Page 24
36
8
14
19
13
34
17
12
18
16
15
8
21
20
23
22
6
7
11
5
9
29
30
8
24
31
8
8
25
32
26
27
26
28
Item
No.
Part
No.
Ref. 804 511-C
Description
Quantity
Figure 8-1. Exploded View Of XR-A AlumaPro Gun
... 1 ..........
... 2 ..........
... 2 ..........
... 3 ..........
................
... 4 ..........
... 5 ..........
... 6 ..........
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
. . . 11 . . . . . . . . . .
. . . 12 . . . . . . . . . .
. . . 12 . . . . . . . . . .
. . . 12 . . . . . . . . . .
231 517
231 519
231 518
227 403
187 316
227 404
227 407
227 406
232 485
135 126
237 515
141 694
189 081
229 887
229 891
232 321
. . Kit, Head Tube Assy (Water) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Head Tube Assy (Air) Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Head Tube Assy (Air) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, W/Spring Plunger (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Pinch Wordless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle Assembly, Left/Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tube, Liner Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief, Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set # 6−32x .12 Knrlpt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set # 6−32x .12 Cup Pt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set 250−20x .37 Conept Sch Stl W/Nyl Patch . . . . . . . . . . . . . . . . . . . .
. . Screw, Set 312−18x .37 Conept Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
5
1
1
1
1
1
1
OM-248 984 Page 25
Item
No.
Part
No.
Description
Quantity
Figure 8-1. Exploded View Of XR-A AlumaPro Gun (Continued)
. . . 13 . . . . . . . . . . 227 608 . . Reducer, Guide Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 227 758 . . Conduit, Monocoil Double Wound 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 227 447 . . Conduit, Monocoil Double Wound 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 231 889 . . Conduit, Monocoil Double Wound 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 144 172 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . .
237 864
Clamp, Hose .375 − .450 Clp Dia Slfttng Green W/Shortened Middle Tab . . . 2
. . . 17 . . . . . . . . . . 134 834 . . Hose, Sae .187 Id X .410 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . Order by Feet
. . . 18 . . . . . . . . . . 191 052 . . Cable, Power/Water Out 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 228 696 . . Cable, Power/Water Out 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 232 055 . . Cable, Power/Water Out 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 234 416 . . Cable Cover Assy, Leather W/Velcro 17 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 234 109 . . Kit, Cable Cover Leather W/Velcro 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 234 110 . . Kit, Cable Cover Leather W/Velcro 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 234 111 . . Kit, Cable Cover Leather W/Velcro 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 227 756 . . Cable, Power 15 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 227 445 . . Cable, Power 25 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 231 887 . . Cable, Power 35 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 235 225 . . Strip, Cop .010 X 1.500 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . 227 757 . . Cable, Control 15 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 227 446 . . Cable, Control 25 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 231 888 . . Cable, Control 35 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 236 836 . . Cable, Control 15 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 236 837 . . Cable, Control 25 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 236 838 . . Cable, Control 35 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 227 452 . . Potentiometer Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . 231 443 . . Screw, 006−32x .44 Soc Hd−Hex Gr8 Pld Lkg Patch . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 134 624 . . Washer, Shldr.140id 0.187odx.094t .375odx.031t Nyl . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . 227 439 . . Drive Roll Assy, Idler .645 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 245 081 . . Trigger Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 234 782 . . Drive Motor Assy, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . ++232 483 . . Drive Assy, Replacement Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . ++232 484 . . Drive Assy, Replacement Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 226 588 . . Screw, 010-32x .37 Btn Hd-Soc Sst Lkg Patch . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 227 434 . . Drive Roll, Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 227 408 . . Guide, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . 196 177 . . Hose, Water Out 10 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 191 072 . . Hose, Water In 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 229 892 . . Hose, Water In 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 232 056 . . Hose, Water In 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 202 513 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . 229 853 . . Guide, Cone Outlet Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . 229 852 . . Guide, Collet Outlet .030−1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . 079 974 . . O−Ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . 193 896 . . Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . 187 029 . . Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . 203 539 . . Fitting, Liner Double Wound Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . 189 811 . . Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . 149 332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 44 . . . . . . . . . . 189 812 . . Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . 227 449 . . Jacket, Cable 3 Ft 4 in. (Power Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . 203 560 . . Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . 203 562 . . Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . 137 495 . . Ftg, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . 089 120 . . Clamp, Hose .375 − .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . . . . . . . 2
++ Drive assemblies include drive housing, pressure arm, pressure arm pin, pressure arm lever, power block assy,
drive shaft assy, pressure arm shaft, tube liner, O-ring, set screws, and springs.
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-248 984 Page 26
. Hardware is common and
7
not available unless listed.
10
9
6
5
8
4
3
2
1
804 706-A
Figure 8-2. (Water) Head Tube Assembly Of AlumaPro Gun
Item
No.
Part
No.
Description
Quantity
Figure 8-2. (Water) Head Tube Assembly Of AlumaPro Gun (Figure 8-1 Item 1)
................
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
................
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
231 517
199 618
206 189
229 670
230 420
227 416
229 889
230 970
194 261
210 771
191 191
229 431
. . Kit, Head Tube Assy Water AlumaPro (Long) (Includes) . . . . . . . . . . . . . . . . . .
. . . . Nozzle, Copper 5/8 in. Orifice Tapered Heavy Duty . . . . . . . . . . . . . . . . . . . .
. . . . Tip, Fastip .312 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diffuser, .281/.312 Od Fastip 1/8 Tip Rec AlumaPro . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Outer Water Long Fastip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Headtube Rotation Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Replacement O-Rings Head Tube Water (Includes) . . . . . . . . . . . . . . . . . .
. . . . . 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 X 8.250 (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
3
1
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-248 984 Page 27
. Hardware is common and
8
not available unless listed.
7
6
5
4
3
2
1
804 705-A
Figure 8-3. (Air) Head Tube Assembly Of AlumaPro Gun
Item
No.
Part
No.
Description
Quantity
Figure 8-3. (Air) Head Tube Assembly Of AlumaPro Gun (Figure 8-1 Item 2)
................
................
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 4 ..........
... 5 ..........
... 6 ..........
................
... 7 ..........
... 8 ..........
... 8 ..........
231 518
231 519
198 855
206 189
229 670
229 673
227 159
227 416
227 168
230 969
191 191
229 431
230 239
. . Kit, Head Tube Assy Air (Long) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Head Tube Assy Air (Short) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nozzle, Copper 5/8 in. Orifice Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tip, Fastip .312 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diffuser, .281/.312 Od Fastip 1/8 Tip Rec AlumaPro . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Outer Air (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Outer Air (Short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Headtube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Replacement O-Rings Head Tube Air (Includes) . . . . . . . . . . . . . . . . . . . . .
. . . . . O-Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Liner, Teflon .047−.062 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Liner, Teflon .047−.062 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
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-248 984 Page 28
SECTION 9 − PARTS LIST INCLUDING CONSUMABLES
Item
Number
1
2
3
4
5
XR-AlumaPro
4” Head Tube
Inner Rear
(#227 416)
(#230 679)
Air (Short)
(#231 519)
Outer
Air Short
XR-AlumaPro
6” Head Tube
(#227 159)
.030−1/16”
(#229 670)
Air (Long)
(#231 518)
Outer
Air Long
(#229 673)
XR-AlumaPro
6” Head Tube
(#230 678)
Outer
Water Long
(#230 420)
Water
(#231 517)
Ref. 803 909-A / 805 046-A / 805 047-A / 805 048-A
Figure 9-1. Consumables Flowchart
Item
No.
Part
No.
Description
Quantity
9-1. Consumables Flowchart
Table 9-1. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . .
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
1
1
1
1
1
OM-248 984 Page 29
Table 9-2. Heavy Duty FasTiptContact 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 9-3. 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 9-4. 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 9-5. Insulators
...
...
...
...
4
4
4
4
..........
..........
..........
..........
227 416
227 159
229 673
230 420
..
..
..
..
Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Outer Air Short (4 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Outer Air Long (6 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Outer Water Long FasTip (6 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
Table 9-6. Head Tube Assemblies
. . . 5 . . . . . . . . . . 231 517 . . Kit, Head Tube Assy Water (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 231 518 . . Kit, Head Tube Assy Air (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 231 519 . . Kit, Head Tube Assy Air (Short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 9-7. FasTip Head Tube LIners (Not Shown)
................
................
................
................
................
................
229 674
227 161
229 431
230 239
233 998
233 999
..
..
..
..
..
..
Liner, Teflon .030−.035 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Teflon .030−.035 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Teflon .047−.062 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Teflon .047−.062 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Phos Bronze .030−1/16 Wire (Short Aluma−Pro) . . . . . . . . . . . . . . . . . . .
Liner, Phos Bronze .030−1/16 Wire (Long Aluma−Pro) . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
Table 9-8. 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-248 984 Page 30
Effective January 1, 2011
(Equipment with a serial number preface of MB 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 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
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
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.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
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
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of 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)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (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 2011−01
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
© 2011 Miller Electric Mfg. Co.
2011−01
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