Miller XR-AlumaPro Series Owner'S Manual Download Page 1

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XR - AlumaPro

(Air And Water-Cooled Guns)

300 Ampere (Air) Push-Pull Welding Gun

Processes

Description

MIG (GMAW) Welding

OM-227398S

2019−05

Semi-Automatic, Air/Water-
Cooled, MIG (GMAW) Welding
Gun

™

File: MIG (GMAW)

400 Ampere (Water) Push-Pull Welding Gun

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

CE And Non-CE Models

Summary of Contents for XR-AlumaPro Series

Page 1: ...n Processes Description MIG GMAW Welding OM 227398S 2019 05 Semi Automatic Air Water Cooled MIG GMAW Welding Gun File MIG GMAW 400 Ampere Water Push Pull Welding Gun For product information Owner s Ma...

Page 2: ...roducts 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 he...

Page 3: ...er Source Having A 14 Socket Receptacle 8 5 2 Air Cooled Gun Connections 9 5 3 Water Cooled Gun Connections 10 5 4 Millermatic 350P Water Cooled Gun Connections 11 5 5 Threading Welding Wire For Aluma...

Page 4: ...ratus Identification Product Stock Number XR W ALUMA PRO 300003 300004 300265 XR W ALUMA PRO PLUS 300003001 300004001 Council Directives 2014 35 EU Low Voltage 2011 65 EU Restriction of the use of cer...

Page 5: ...ding power source before changing contact tip or gun parts D Keep all covers and handle securely in place FUMES AND GASES can be hazardous D Keep your head out of the fumes D Ventilate area or use bre...

Page 6: ...nd Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org S...

Page 7: ...erre D Ne jamais toucher une lectrode ou des pi ces lectriques sous tension D Remplacer les pistolets ou c bles de soudage qui sont endom mag s us s ou craquel s D Mettre la soudeuse hors tension avan...

Page 8: ...ndard 70 from National Fire Protec tion Association Quincy MA 02169 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Co...

Page 9: ...facility Contact your local recycling office or your local distributor for further information Safe37 2017 04 3 2 Miscellaneous Symbols And Definitions V Volts Alternating Cur rent X Duty Cycle Wire...

Page 10: ...ions Operating Temperature Range Storage Temperature Range 14 to 104 F 10 to 40 C 4 to 131 F 20 to 55 C Temp_2016 07 C Information On Electromagnetic Fields EMF This equipment shall not be used by the...

Page 11: ...verheating NOTICE Exceeding duty cycle can damage unit and void warranty sduty1 5 95 Air Cooled Models Continuous Welding 100 Duty Cycle At 300 Peak Amperage Using 100 Argon Gas w 15 25 Or 35 Foot Gun...

Page 12: ...V Or Constant Current Constant Voltage CC CV Welding Power Source Having A 14 Socket Receptacle Ref 804653 A 805349 A 1 CC CV Or CC CV Welding Power Source 2 24 VAC Contactor Control 14 Pin Plug 3 Neg...

Page 13: ...ntrol Cable Insert plug into Gun Control receptacle and tighten threaded collar 2 Gun Power Pin 3 Gun Bushing 4 Gun Securing Knob 5 Drive Casting Loosen gun securing knob and insert gun power pin thro...

Page 14: ...Gun Bushing 5 Drive Casting 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 Gun Coolant In Hose Connec...

Page 15: ...le and tighten threaded collar 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 throug...

Page 16: ...eling Open pressure assembly Pull and hold wire cut off end 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...

Page 17: ...bly out straight 2 Jog Switch Push Jog switch up to feed wire through cable assembly 3 Torque Switch Select proper push feeder torque set ting for wire size being used Use low torque for 030 in 0 8mm...

Page 18: ...1 Tension Arm Open tension arm Thread wire thru inlet guide along drive roll groove and into wire conduit Close tension arm Adjust tension as follows Hold wire tightly to keep it from unraveling 1 1 W...

Page 19: ...ect to pin B D Trigger E Wire speed Ref 9 volts DC H Wire speed com F Wire speed 0 to 9 volts DC with respect to pin H J Gun sensing resistor with respect to pin H I Not used 5 9 Opening Top Cover Of...

Page 20: ...ding Wire Through Gun Ref 804544 B 804545 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 latch wir...

Page 21: ...ise to decrease wire speed Speed control can be rotated more than 3 3 4 turns in both di rections without being damaged 1 2 Ref 804545 B 6 2 Gun Pressure Roll Tension Setting Aluminum series specific...

Page 22: ...table below for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished welding 1 3 2 MILLER Aluminum Protecting Coolant No 043 809 Distilled Or Deionized Water...

Page 23: ...ire 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 rol...

Page 24: ...d tube Insert new liner into head tube install tapered end first and reinstall 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 h...

Page 25: ...ner 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 assembly...

Page 26: ...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 27: ...ozzle 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 de bris Reinstall liner assembly into gu...

Page 28: ...atically Check conduit for wear and obstruction and replace if necessary Check contact tip for correct size and replace if necessary Check pressure roll tension setting see Section 6 2 Check for prope...

Page 29: ...OM 227398 Page 25 SECTION 8 ELECTRICAL DIAGRAMS 228669 B Figure 8 1 Circuit Diagram For XR AlumaPro Gun Notes...

Page 30: ...age 26 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 A Al...

Page 31: ...ir 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 32: ...1 24 227452 Potentiometer Assy 1 25 231443 Screw 006 32x 44 Soc Hd Hex Gr8 Pld Lkg Patch 1 26 134624 Washer Shldr 140id 0 187odx 094t 375odx 031t Nyl 2 27 227439 Drive Roll Assy Idler 645 Od 1 28 2450...

Page 33: ...r local distributor Hardware is common and not available unless listed 804706 A 1 2 3 4 5 10 6 9 7 8 Figure 9 2 Water Head Tube Assembly Of AlumaPro Gun Item No Part No Quantity Description Figure 9 2...

Page 34: ...Short Includes 1 1 198855 Nozzle Copper 5 8 in Orifice Tapered 1 2 206189 Tip Fastip 312 Od 052 And 3 64al Wires 1 3 229670 Diffuser 281 312 Od Fastip 1 8 Tip Rec AlumaPro 1 4 229673 Insulator Outer A...

Page 35: ...ht 1 1 199612 Nozzle Screw On Brass 3 4 in Orifice Straight Heavy Duty 1 1 199613 Nozzle Screw On Brass 5 8 in Orifice 1 1 199614 Nozzle Screw On Brass 5 8 in Orifice Heavy Duty 1 1 199615 Nozzle Scre...

Page 36: ...r Outer Air Short 4 in 1 4 229673 Insulator Outer Air Long 6 in 1 4 230420 Insulator Outer Water Long FasTip 6 in 1 Table 10 6 Head Tube Assemblies 5 231517 Kit Head Tube Assy Water Long 1 5 231518 Ki...

Page 37: ...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 38: ...Notes...

Page 39: ...semblies TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Pa...

Page 40: ...h 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 Equi...

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