OM-227 398D
2007−12
Processes
MIG (GMAW) Welding
Description
Semi-Automatic,Air/Water-
Cooled, MIG (GMAW) Welding
Gun
™
XR - Aluma-Pro
(Air And Water-Cooled Guns)
300 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) Push-Pull Welding Gun
File: MIG (GMAW)
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TABLE OF CONTENTS
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle . . . . . . . . . . . . . . . . . . . . . .
4-2. XR-Water-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Millermatic 350P Water Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Threading Welding Wire For Aluma-Pro Gun And Millermatic 350P . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Threading Welding Wire Through XR-Control Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-6. Adjusting Tension At Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-7. 10-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-8. Opening Top Cover Of XR-Aluma-Pro Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-9. Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Gun Pressure Roll Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-3. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-4. Coolant Supply For Water-Cooled Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-5. Gun Drive Assembly Maintenance For An XR-Aluma-Pro Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-6. Replacing Head Tube Liner In XR-Aluma-Pro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-7. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-8. Replacing The Gun Liner On XR-Aluma-Pro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-1. Routine Maintenance For Aluminum Push/Pull Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-2. Cleaning The Gun Liner On XR-Aluma-Pro Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 9 − PARTS LIST INCLUDING CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
XR - Aluma-Pro
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Standards
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 7: Torches. IC 60974-7 Ed.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_wire_6/05
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SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7_2007−04
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 special instructions.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
BUILDUP OF GAS can injure or kill.
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.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Only qualified persons should install, operate, maintain, and
repair this unit.
D
Wear welding helmet with correct shade of fil-
ter.
During operation, keep everybody, especially children, away.
D
D
Wear correct eye and body protection.
Cover exposed skin with spatter-resistant
clothing.
ELECTRIC SHOCK can kill.
D
D
D
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrode or electrical parts.
HOT PARTS can cause severe burns.
D
D
D
Allow gun to cool before touching.
Do not touch hot metal.
Protect hot metal from contact by others.
D
D
D
Repair or replace worn, damaged, or cracked gun or cable insula-
tion.
Turn off welding power source before changing contact tip or gun
parts.
Keep all covers and handle securely in place.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
FUMES AND GASES can be hazardous.
D
Check for noise level limits exceeding those
specified by OSHA.
D
D
D
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for material
used.
D
D
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
WELDING WIRE can cause injury.
WELDING can cause fire or explosion.
D
Keep hands and body away from gun tip when
trigger is pressed.
D
D
D
Do not weld near flammable material.
Do not weld on closed containers.
Watch for fire; keep extinguisher nearby.
OM-227 398 Page 1
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1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
About Implanted Medical Devices:
ImplantedMedical 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 recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-227 398 Page 2
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SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
A
B
C
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1
Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or
power before working on
machine.
2
Breathing welding fumes can
be hazardous to your health.
2.2
2.3
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3
4
5
3.2
3.3
3
Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
+ + +
3.3 Do not weld on drums or any
closed containers.
4
Arc rays can burn eyes and
injure skin.
6
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
+
S-178 936
5
Become trained and read the
instructions before working on
the machine or welding.
6
Do not remove or paint over
(cover) the label.
OM-227 398 Page 3
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2-2. Manufacturer’s Rating Label For CE Products Only
229 109-A
2-3. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-
plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
2-4. Symbols And Definitions
. Some symbols are found only on CE products.
Amperes
Volts
Alternating Current
Circuit Breaker
Duty Cycle
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Wire Feed
Gun
Jog
Output
Trigger
Press To Set
Increase
Trigger Hold On
Trigger Hold Off
Run-In
Purge
Spot Weld Time
Primary Voltage
Percent
Burnback Time
Primary Current
Load Voltage
Read Instructions
U1
I2
U2
Water (Coolant) In-
put
Rated Current
Fuse
Line Connection
I1
Water (Coolant)
Output
Continuous
Spot Welding
OM-227 398 Page 4
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SECTION 3 − INTRODUCTION
3-1. Specifications
Model
Welding Output Range
Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
(Torch Only)
XR-Aluma-Pro Gun
(Air Cooled)
300 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)
2.5 lb (1.1 kg)
(less cables)
XR-Aluma-Pro 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 changing 1/16 in (1.6 mm) wire, kit 230708 must be installed.
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Air-Cooled Models
100% Duty Cycle At 300 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
ContinuousWelding
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-227 398 Page 5
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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 Re-
ceptacle
1
2
CC, CV Or CC/CV Welding
Power Source
24 VAC/Contactor Control
14-Pin Plug
3
4
Workpiece
Voltage Sensing Lead
(Optional)
1
Connect lead to workpiece for CC
welding only.
5
6
7
Gun
2
8
Wire Feeder
24 VAC/Contactor Control
Cord
Do not use gas pressure
above 50 psi (345 kPa).
8
Gas Cylinder
3
8
6
7
4
5
XR Control
1
5
Millermatic 350P
804 542-B / 804 653-A
OM-227 398 Page 6
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4-2. XR-Water-Cooled Gun Connections
. Turn on coolant supply before
welding or gun will be dam-
aged.
1
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
2
3
4
Gun Connector
Gun Securing Knob
Gun Connector Block
3
Loosen gun securing knob, and
insert gun connector through Wire
opening until it bottoms against
block. Tighten knob. Close and
latch door.
2
4
5
Gun (Coolant) “In” Hose
Connect to Water “In” fitting on
feeder (left-hand threads).
6
Gun (Coolant) “Out” Hose
Connect to Water “Out” fitting on
feeder (left-hand threads)
7
8
9
Water (Coolant) Output
Water (Coolant) Input
Left Side
7
8
XR Control (Coolant) Output
10 XR Control (Coolant) Input
Close and latch door.
9
10
6
Tools Needed:
9/16 in
1
5
Ref. 801 577-A / 805 106-A
OM-227 398 Page 7
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4-3. Millermatic 350P Water Cooled Gun Connections
8
7
1
2
Ref. 804 945-A
6
5
3
4
Tools Needed:
9/16 in
4
Water In Hose
bottoms against block. Tighten knob. Close
and latch door.
. Turn on coolant supply before welding
or gun will be damaged.
Connect to coolant supply with supplied
coupler and water hose (left-hand threads).
6
Water Out Hose
1
2
3
Coolant Supply
Millermatic 350P
Gun Control Cable
Connect to coolant supply with supplied
coupler and water hose (left-hand threads).
5
Gun Connector
7
8
Coolant “In”
Insert plug into gun control receptacle and
tighten threaded collar.
Loosen gun securing knob, and insert gun
connector through Wire opening until it
Coolant “Out”
OM-227 398 Page 8
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4-4. Threading Welding Wire For Aluma-Pro Gun And Millermatic 350P
1
2
3
4
5
6
7
8
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
7
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
Pressure
1
2
3
4
4
Indicator
Scale
218244−A
Push wire thru guides into gun;
continue to hold wire.
Close and tighten pressure
assembly, and let go of wire.
. Set pressure indicator
scale to 1/2 lb.
wire through Aluma-Pro guns.
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
OM-227 398 Page 9
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4-5. Threading Welding Wire Through XR-Control Feeder
1
Cable Assembly
Lay cable assembly out straight.
Jog Switch
2
Tools Needed:
Push Jog switch up to feed wire through
cable assembly.
2
1
Ref. 802 193-A
4-6. Adjusting Tension At Feeder
Tools Needed:
. Hold wire tightly to keep
it from unraveling.
6 in
(150 mm)
Open tension arm.
Pull and hold wire; cut off end.
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension as
follows: grasp spool with one hand, press Jog switch, and
turn thumb nut clockwise until motor stalls when Jog
switch is pressed. Back thumb nut off slightly.
Ref. 802 193-A
OM-227 398 Page 10
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4-7. 10-Pin Plug Information
Pin*
Pin Information
10
A
B
G
C
D
E
H
F
J
Electrode sense lead
Motor Common
Trigger
E
B
F
D
C
Motor 0 to +24 volts dc with respect to pin B
Trigger
J
G
I
H
A
Wire speed Ref. +9 volts dc
Wire speed com
Wire speed 0 to +9 volts dc with respect to pin H
Gun sensing resistor with respect to pin H
Not used
I
4-8. Opening Top Cover Of XR-Aluma-Pro 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-227 398 Page 11
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4-9. Threading Welding Wire Through Gun
wire through feeder.
For XR-Aluma-Pro Gun:
Welding wire is electrically live when
gun trigger is used to jog wire.
. Turn OFF coolant supply before threading wire
Lay gun cable out straight. Press Jog switch until about 6
in (152 mm) of wire is sticking out end of contact tip.
through gun..
. Verify pressure adjustment
on handle matches the wire
Cut off wire. Close and
latch wire feeder door.
Tools Needed:
Ref. 804 544-B / 804 545-B
OM-227 398 Page 12
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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
adjustmentfrom minimum to maxi-
mum.
1
2
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 stain-
less 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:
Ref. 804 545-B
OM-227 398 Page 13
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5-3. Shielding Gas
1
2
3
ShieldingGas Cylinder
Valve
Gun Trigger
2
Open valve on cylinder just before
welding.
1
Gun trigger turns weld output and
gas flow on and off (see Section
5-1).
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.
1
Turn On coolant supply before
welding.
3
Turn Off coolant supply when
finished welding.
2
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
GTAW Or Where
HF* Is Used
Application
MILLER Aluminum Protecting
Coolant No. 043 809**;
MILLER Low
Conductivity Coolant
No. 043 810**
Distilled Or Deionized Water OK
Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Ref. 150 755-A
OM-227 398 Page 14
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5-5. Gun Drive Assembly Maintenance For An XR-Aluma-Pro 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
2
Thread welding wire through gun.
Close pressure roll assembly and
idler roll (located in XR control box).
Press jog switch until wire is stick-
ing out end of contact tip.
. 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:
5/16 in
Ref. 804 544-B
OM-227 398 Page 15
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5-6. Replacing Head Tube Liner In XR-Aluma-Pro Guns
. Turn OFF coolant supply before
removing head tube on
water-cooled gun.
The standard head tube liner will ac-
commodate wire diameters from
.030-.035wire size.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized lin-
er.
3
1
2
Head Tube
Head Tube Nut
2
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
. A twisting motion may be need-
ed to feed liner thru head tube.
Tapered end
. Be sure head tube is seated and
head tube nut is securely tight-
ened 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
2
Nozzle
FasTip
Unscrew FasTip.
Install new FasTip.
. Make sure correct size con-
tact tip is being used. Incor-
rect size may cause arcing in-
side tip, poor feedability and
poor arc starting characteris-
tics(see Section 9).
Reinstall nozzle.
2
1
Ref. 804 709-A
OM-227 398 Page 16
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5-8. Replacing The Gun Liner On XR-Aluma-Pro 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
2
7
Power Pin End
. Gently pry open
slots to remove
wire collet guide.
. Cut liner flush with
wire collet guide.
Ref. 804 546-A
Remove short leather cover to access liner
assembly.
liner is through power pin assembly and is
visible.
!
Turn Off welding power source and
wire feeder.
Loosen liner lock allen screw (located near
back of handle) to remove liner guide re-
ducer from gun.
1
2
3
4
5
6
7
Leather Cover
Liner
Install liner assembly into gun and tighten
liner lock allen screw.
Liner Lock Allen Screw
Liner Guide Reducer
Wire Guide Cone
Wire Collet Guide
Power Pin
Reinstall wire collet guide at power pin and
tighten onto liner.
Remove wire guide cone and wire collet
guide from power pin.
Cut liner off flush with wire collet guide. Re-
install wire guide cone.
Remove old liner from gun end (see il-
lustration above).
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-227 398 Page 17
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SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance For Aluminum Push/Pull Guns
!
Disconnect power
before maintaining.
n = Check
~ = Clean
l = Replace
Daily
n~ Head Tube Liner and
Drive Casting
Weekly
n~ Drive Roll
Every
Spool
of Wire
Or
n~ Nozzle / Contact Tip
~ Gun Casing
n~ Gun Liner
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
n 14-Pin Cord
n Gas Hose and Fittings
n Gun Cable
OM-227 398 Page 18
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6-2. Cleaning The Gun Liner On XR-Aluma-Pro Guns
1
2
3
Gun End
5
4
Power Pin End
Ref. 804 546-A
sembly.
Loosen liner lock allen head screw (located
near back of handle) to remove liner guide
reducer from gun.
!
Turn Off welding power source
and wire feeder.
2
3
4
5
Liner Guide Reducer
Blow air from power pin end through liner
until clean of debris.
Lay gun cable out straight.
Leather Cover
Remove leather cover to access liner as-
Liner Lock Allen Head Screw
Power Pin
1
Reinstall liner assembly into gun and tight-
en liner lock allen head screw when fin-
ished cleaning.
Air Nozzle
OM-227 398 Page 19
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6-3. Troubleshooting Table
Disconnect power before troubleshooting.
Remedy
Trouble
Reset circuit breaker in feeder/control box. See feeder/control owner’s manual.
Replace trigger-switch and test operation.
No wire feed at gun, feeder not operat-
ing. Check motor or brake solenoid.
Check trigger-switch wires for continuity.
Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s
manual.
No wire feed at gun, feeder operating
properly.
Check potentiometer with meter and replace if necessary.
Check motor and potentiometer wires for continuity.
See feeder/control owner’s manual.
Clean and tighten all power connections.
Wire feeds, but welding wire is not ener-
gized.
See feeder/control owner’s manual.
Check operation of welding power source.
Check conduit for wear and obstruction and replace if necessary.
Check contact tip for correct size and replace if necessary.
Check for proper head tube liner (see Table 9-7).
Wire feeds erratically.
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.
Wire feeds one speed only.
Secure plug from gun control cable into gun control receptacle on feeder.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Pressing gun trigger does not energize
feeder. Welding wire is not energized.
Shieldinggas 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-227 398 Page 20
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12
13
7
17
11
32
15
16
10
14
18
19
21
20
6
7
9
5
8
27
7
28
29
22
7
23
30
24
25
24
26
Ref. 804 511-B
Item
No.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . 231 517 . . Kit, Head Tube Assy (Water) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 231 519 . . Kit, Head Tube Assy (Air) Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 231 518 . . Kit, Head Tube Assy (Air) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 227 403 . . Cover, W/Spring Plunger (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 187 316 . . . Label, Pinch Wordless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 227 404 . . Handle Assembly, Left/Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 227 407 . . Tube, Liner Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 227 406 . . Strain Relief, Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 232 485 . . Screw, Set # 6−32x .12 Knrlpt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 8 . . . . . . . . . . 141 694 . . Screw, Set 312−18x .37 Conept Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . 189 081 . . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-227 398 Page 23
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Item
No.
Part
No.
Description
Quantity
. . . 10 . . . . . . . . . . 229 887 . . Liner, Replacement 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 229 891 . . Liner, Replacement 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 232 321 . . Liner, Replacement 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 227 608 . . Reducer, Guide Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 227 758 . . Conduit, Monocoil Double Wound 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 227 447 . . Conduit, Monocoil Double Wound 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 231 889 . . Conduit, Monocoil Double Wound 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 144 172 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . 149 332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . 134 834 . . Hose, Sae .187 Id X .410 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . Order by Feet
. . . 16 . . . . . . . . . . 191 052 . . Cable, Power/Water Out 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 228 696 . . Cable, Power/Water Out 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 232 055 . . Cable, Power/Water Out 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 234 416 . . Cable Cover Assy, Leather W/Velcro 17 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 234 109 . . Kit, Cable Cover Leather W/Velcro 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 234 110 . . Kit, Cable Cover Leather W/Velcro 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 234 111 . . Kit, Cable Cover Leather W/Velcro 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 227 756 . . Cable, Power 15 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 227 445 . . Cable, Power 25 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 231 887 . . Cable, Power 35 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 235 225 . . Strip, Cop .010 X 1.500 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . 227 757 . . Cable, Control 15 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 227 446 . . Cable, Control 25 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 231 888 . . Cable, Control 35 Ft (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 236 836 . . Cable, Control 15 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 236 837 . . Cable, Control 25 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 236 838 . . Cable, Control 35 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 227 452 . . Potentiometer Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 231 443 . . Screw, 006−32x .44 Soc Hd-Hex Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 134 624 . . Washer, Shldr.140id 0.187odx.094t .375odx.031t Nyl . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . 227 439 . . Drive Roll Assy, Idler .645 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 227 466 . . Trigger Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 234 782 . . Drive Motor Assy, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 232 483 . . Drive Assy, Replacement Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 232 484 . . Drive Assy, Replacement Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 226 588 . . Screw, 010-32x .37 Btn Hd-Soc Sst Lkg Patch . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 227 434 . . Drive Roll, Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 227 408 . . Guide, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 196 177 . . Hose, Water Out 10 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 191 072 . . Hose, Water In 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 229 892 . . Hose, Water In 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 232 056 . . Hose, Water In 35 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . 202 513 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . 229 853 . . Guide, Cone Outlet Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 229 852 . . Guide, Collet Outlet .030−1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . 079 974 . . O−Ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . 193 896 . . Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . 187 029 . . Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . 203 539 . . Fitting, Liner Double Wound Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . 189 811 . . Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . 149 332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . 189 812 . . Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . 227 449 . . Jacket, Cable 3 Ft 4 In (Power Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . 203 560 . . Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . 203 562 . . Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . 137 495 . . Ftg, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-227 398 Page 24
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10
9
. Hardware is common and
7
not available unless listed.
6
5
8
4
3
2
1
804 706-A
Figure 8-2. (Water) Head Tube Assembly Of Aluma-Pro Gun
Part
Item
No.
Description
No.
Quantity
. . . . . . . . . . . . . . . . 231 517 . . Kit, Head Tube Assy Water Aluma−Pro (Long) (Includes) . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . 199 618 . . . . Nozzle, Copper 5/8 In Orifice Tapered Heavy Duty . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206 189 . . . . Tip, Fastip .312 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 229 670 . . . . Diffuser, .281/.312 Od Fastip 1/8 Tip Rec Aluma Pro . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 230 420 . . . . Insulator, Outer Water Long Fastip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 227 416 . . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 229 889 . . . . Nut, Headtube Rotation Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230 970 . . . . Kit, Replacement O-Rings Head Tube Water (Includes) . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 194 261 . . . . . O−Ring, .551 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . 210 771 . . . . . O−Ring, 14.99mm Id X 1.27mm Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 191 191 . . . . . O−Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . 229 431 . . . . Liner, Teflon .047−.062 Wire X 8.250 (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . 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-227 398 Page 25
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8
. Hardware is common and
not available unless listed.
7
6
5
4
3
2
1
804 705-A
Figure 8-3. (Air) Head Tube Assembly Of Aluma-Pro Gun
Item
No.
Part
No.
Description
Quantity
. . . . . . . . . . . . . . . . 231 518 . . Kit, Head Tube Assy Air (Long) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 231 519 . . Kit, Head Tube Assy Air (Short) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . 198 855 . . . . Nozzle, Copper 5/8 In Orifice Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206 189 . . . . Tip, Fastip .312 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 229 670 . . . . Diffuser, .281/.312 Od Fastip 1/8 Tip Rec Aluma Pro . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 229 673 . . . . Insulator, Outer Air (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 227 159 . . . . Insulator, Outer Air (Short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 227 416 . . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 227 168 . . . . Nut, Headtube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230 969 . . . . Kit, Replacement O-Rings Head Tube Air (Includes) . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 191 191 . . . . . O-Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . 229 431 . . . . Liner, Teflon .047−.062 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 230 239 . . . . Liner, Teflon .047−.062 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . 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-227 398 Page 26
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SECTION 9 − PARTS LIST INCLUDING CONSUMABLES
1
2
3
4
5
Item
Number
XR-Aluma-Pro
4” Head Tube
Inner Rear
(#227 416)
Air (Short)
(#231 519)
Outer
Air Short
(#227 159)
XR-Aluma-Pro
6” Head Tube
(#230 679)
.030−1/16”
Air (Long)
(#231 518)
(#229 670)
(#230 678)
Outer
Air Long
(#229 673)
XR-Aluma-Pro
6” Head Tube
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 . . . . . . . . ♦199 610 . . Nozzle, Screw On Brass 1/2 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 611 . . Nozzle, Screw On Brass 3/4 in Orifice Straight . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 612 . . Nozzle, Screw On Brass 3/4 in Orifice Straight Heavy Duty . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 613 . . Nozzle, Screw On Brass 5/8 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 614 . . Nozzle, Screw On Brass 5/8 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 615 . . Nozzle, Screw On Copper 1/2 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 616 . . Nozzle, Screw On Copper 3/4 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦199 617 . . Nozzle, Screw On Copper 3/4 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . 198 855 . . Nozzle, Screw On Copper 5/8 in Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . 199 618 . . Nozzle, Screw On Copper 5/8 in Orifice Heavy Duty . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦207 313 . . Nozzle, Screw On Copper 5/8 in Orifice 15/16 OD . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . ♦209 035 . . 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
. . . 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
OM-227 398 Page 27
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Table 9-2. Heavy Duty FasTiptContact Tips*
. . . 2 . . . . . . . . ♦206 185 . . .030 in (0.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . ♦206 186 . . .035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206 187 . . .040 in (1.0 mm) or .035 in (0.9 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . ♦206 188 . . .045 in (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206 189 . . .052 in (1.3 mm) or 3/64 in (1.2 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . ♦206 190 . . 1/16 in (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . ♦206 191 . . .068 in (1.7 mm) or 1/16 in (1.6 mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . . . 1
Table 9-3. Tapered FasTipt Contact Tips*
. . . 2 . . . . . . . . . ♦209025 . . .030 in (0.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . ♦209026 . . .035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . ♦209027 . . .045 in (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . ♦209028 . . 3/64 in (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . ♦209029 . . .052 in (1.3 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . ♦209030 . . 1/16 in (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . 227 416 . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 227 159 . . Insulator, Outer Air Short (4 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 229 673 . . Insulator, Outer Air Long (6 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 230 420 . . Insulator, Outer Water Long FasTip (6 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . Liner, Teflon .030−.035 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 227 161 . . Liner, Teflon .030−.035 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 229 431 . . Liner, Teflon .047−.062 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230 239 . . Liner, Teflon .047−.062 Wire X Short (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-227 398 Page 28
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Notes
SOCKET/WRENCH SELECTION TABLE
(U.S. STANDARD)
SOCKET/WRENCH SELECTION TABLE
(METRIC)
Specifications
Bolt Decimal
Socket or Wrench Size
Specifications
U.S.
Socket or Wrench Size
Bolt
Bolt
Nut
Decimal
Bolt
Nut
Diameter Equivalent
Diameter
Equivalent
1/4 in
5/16 in
3/8 in
7/16 in
1/2 in
9/16 in
5/8 in
3/4 in
7/8 in
1 in
.250 in
.3125 in
.375 in
.4375 in
.500 in
.5625 in
.625 in
.750 in
.875 in
1.000 in
3/8 in
1/2 in
7/16 in
9/16 in
5/8 in
6 mm
8 mm
.2362 in
.3150 in
.3937 in
.4724 in
.5512 in
.6299 in
.7087 in
.8661 in
.9449 in
10 mm
14 mm
17 mm
19 mm
22 mm
24 mm
27 mm
32 mm
36 mm
10 mm
14 mm
17 mm
19 mm
22 mm
24 mm
27 mm
32 mm
36 mm
9/16 in
5/8 in
10 mm
12 mm
14 mm
16 mm
18 mm
22 mm
24 mm
3/4 in
3/4 in
13/16 in
7/8 in
7/8 in
15/16 in
1-1/8 in
1-5/16 in
1-1/2 in
1 in
1-1/8 in
1-5/16 in
1-1/2 in
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Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
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.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
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.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
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.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
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.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
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.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
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)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
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.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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