Miller XR-A AlumaPro Plus 15 ft Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Proposition 65 Warnings

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1-4.

Principal Safety Standards

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1-5.

EMF Information

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SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION

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2-1.

Signification des symboles

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2-2.

Dangers relatifs au soudage à l’arc

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2-3.

Proposition californienne 65 Avertissements

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2-4.

Principales normes de sécurité

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2-5.

Informations relatives aux CEM

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SECTION 3 − DEFINITIONS

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3-1.

Additional Safety Symbols And Definitions

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3-2.

Miscellaneous Symbols And Definitions

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SECTION 4 − INTRODUCTION

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4-1.

Specifications

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4-2.

Environmental Specifications

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4-3.

Duty Cycle And Overheating

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SECTION 5 − INSTALLATION

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5-1.

Equipment Connection Diagram - Single Feeder

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5-2.

Equipment Connection Diagram - Dual Feeder

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5-3.

14-Pin Plug Information For Connecting Wire Feeder To Power Source

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5-4.

Opening Top Cover Of XR-AlumaPro Plus Gun

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5-5.

Threading Welding Wire Through Gun

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SECTION 6 − OPERATION

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6-1.

Gun Controls

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6-2.

Gun Pressure Roll Tension Setting

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6-3.

Shielding Gas

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6-4.

Coolant Supply For Water-Cooled Models Only

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6-5.

Gun Drive Assembly Maintenance For An XR-AlumaPro Plus Gun

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6-6.

Replacing Head Tube Liner In XR-AlumaPro Plus Guns

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6-7.

Changing Gun Contact Tip

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6-8.

Replacing The Gun Liner On XR-AlumaPro Plus Guns

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SECTION 7 − MAINTENANCE & TROUBLESHOOTING

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7-1.

Routine Maintenance For Aluminum Push/Pull Guns

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7-2.

Cleaning The Gun Liner On XR-AlumaPro Plus Guns

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7-3.

Troubleshooting Table

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SECTION 8 − ELECTRICAL DIAGRAMS

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SECTION 9 − PARTS LIST

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SECTION 10 − PARTS LIST INCLUDING CONSUMABLES

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WARRANTY

Summary of Contents for XR-A AlumaPro Plus 15 ft

Page 1: ...h Pull Welding Gun XR AlumaPro Plus Air And Water Cooled Guns CE And Non CE Models Processes Description MIG GMAW Welding OM 245892J 2017 09 Semi Automatic Air Water Cooled MIG GMAW Welding Gun File M...

Page 2: ...ntinue 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...

Page 3: ...5 INSTALLATION 10 5 1 Equipment Connection Diagram Single Feeder 10 5 2 Equipment Connection Diagram Dual Feeder 11 5 3 14 Pin Plug Information For Connecting Wire Feeder To Power Source 12 5 4 Openi...

Page 4: ...us Identification Product Stock Number XR A ALUMA PRO PLUS 300000003 300001003 XR W ALUMA PRO PLUS 300003001 300004001 Council Directives 2006 95 EC Low Voltage 2011 65 EU Restriction of the use of ce...

Page 5: ...ea or use breathing device The recommended way to determine adequate ventilationis to sample for the composition and quantity of fumes and gases to which personnel are exposed D Read and understand th...

Page 6: ...Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Su...

Page 7: ...a zone de travail ou porter un appareil respiratoire Pour d terminer la bonne ventilation il est recommand de proc der un pr l vementpour la composition et la quantit de fum es et de gaz auxquels est...

Page 8: ...bsite www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788...

Page 9: ...tion facility Contact your local recycling office or your local distributor for further information Safe37 2017 04 3 2 Miscellaneous Symbols And Definitions A Amperes V Volts AlternatingCur rent X Dut...

Page 10: ...ng IP3X This equipment is designed for indoor use and is not intended to be used or stored outside IP3X 2014 06 B Temperature Specifications Operating Temperature Range Storage Temperature Range 14 to...

Page 11: ...anty sduty1 5 95 Air Cooled Models CE Air Cooled Models Continuous Welding 60 Duty Cycle At 250 Peak Amperage Using 100 Argon Gas w 15 25 Or 35 Foot Guns 100 Duty Cycle At 300 Peak Amperage Using 100...

Page 12: ...1 Equipment Connection Diagram Single Feeder 1 Welding Power Source 2 Contactor Control Power Cord 3 Positive Weld Cable 4 Negative Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas...

Page 13: ...actor Control Power Cord 3 Positive Weld Cable 4 Negative Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder and Regulator Customer Supplied Shielding gas pressure not to exc...

Page 14: ...l 6 Trigger 7 Trigger 8 Wire speed ref 5 volts DC 9 Wire speed com 10 Wire speed 0 to 5 volts DC with respect to pin 9 11 Gun sensing resistor with respect to pin 9 12 Not used 13 Not used 14 Not used...

Page 15: ...Welding Wire Through Gun Ref 804 544 B 804 545 B Tools Needed Lay gun cable out straight Press Jog switch until about 6 in 152 mm of wire is sticking out end of contact tip Cut off wire Close and lat...

Page 16: ...trol can be rotated more than 3 3 4 turns in both di rections without being damaged 1 2 Ref 804 545 B 6 2 Gun Pressure Roll Tension Setting Aluminum series specific Pressure roll tension setting ensur...

Page 17: ...t In 3 Coolant Out See table below for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished welding 1 MILLER Aluminum Protecting Coolant No 043 809 Distilled...

Page 18: ...ace 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...

Page 19: ...install head tube onto gun A twisting motion may be need ed 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 nu...

Page 20: ...old liner from gun end see il lustration above Insert new liner into gun end and continue feeding liner through cable assembly until liner is through power pin assembly and is visible Install liner as...

Page 21: ...wer before maintaining n Check Clean l Replace Daily n Head Tube Liner and Drive Casting see Section 6 6 Weekly n Drive Roll Every Spool of Wire Or n Nozzle Contact Tip Gun Casing n Gun Liner see Sect...

Page 22: ...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 Reinstall liner assembly into g...

Page 23: ...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 rep...

Page 24: ...OM 245892 Page 20 SECTION 8 ELECTRICAL DIAGRAMS 244795 B Figure 8 1 Circuit Diagram For XR AlumaPro Plus Gun Notes...

Page 25: ...OM 245892 Page 21 Notes...

Page 26: ...ge 22 SECTION 9 PARTS LIST Hardware is common and not available unless listed 2 3 4 34 33 49 35 39 37 40 35 49 17 41 44 45 46 47 18 21 22 48 10 14 43 42 23 38 36 1 Figure 9 1 Exploded View Of XR Aluma...

Page 27: ...Air Long 1 3 227403 Cover W Spring Plunger Includes 1 187316 Label Pinch Wordless 1 4 227404 Handle Assembly Left Right 1 5 227407 Tube Liner Stainless 1 6 227406 Strain Relief Cable Control 1 7 M1476...

Page 28: ...Drive Roll Knurled 1 32 227408 Guide Inlet 1 33 196177 Hose Water Out 10 In 1 34 191072 Hose Water In 15 Ft 1 34 229892 Hose Water In 25 Ft 1 35 202513 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 2 36 M1...

Page 29: ...ntact Tip 035 0 9mm 1 4 D 1AP Diffuser Centerfire D 1AP 1 5 230420 Insulator Outer Water Long Fastip 1 6 229889 Nut Headtube Rotation Water 1 7 227416 Insulator Ring Inner Rear 1 230970 Kit Replacemen...

Page 30: ...1 8 in 1 2 T 035AL Centerfire Contact Tip 035 0 9mm 1 3 D 1AP Diffuser Centerfire D 1AP 1 4 229673 Insulator Outer Air Long 1 5 227168 Nut Headtube Rotation 1 6 227416 Insulator Ring Inner Rear 1 230...

Page 31: ...14C Nozzle C Fire Large Copper 3 4 in Recess 1 4 in 1 1 3414 HD Centerfire Nozzle Cone 3 4 in Id 1 4 in Recess 1 1 5818 HD Centerfire Nozzle Cone 5 8 in Id 1 8 in Recess 1 1 N HDC HD Centerfire Nozzle...

Page 32: ...Fastip 1 233999 Liner Phos Bronze 030 1 16 Wire Long Aluma Pro 1 Table 10 7 Wire Kit Not Shown 230708 Kit Idler Roll 1 16 062 1 198377 Hardwire Liner Kit 30W For Steel Stainless 1 OPTIONAL All contact...

Page 33: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 34: ...Notes...

Page 35: ...Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable co...

Page 36: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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