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Summary of Contents for Miller XR-Pistol-Plus
- Page 1 OM-248663K 2019−05 Processes MIG (GMAW) Welding Description Semi-Automatic, Air/Water- Cooled, MIG (GMAW) Welding XR - Pistol - Plus (Air And Water-Cooled Guns) File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING ..1-1. Symbol Usage ............... . 1-2. -
Page 5: Section 1 −Safety Precautions For Gmaw Welding Guns − Read Before Using
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7 (MIG) 2018-01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. -
Page 6: Proposition 65 Warnings
NOISE can damage hearing. READ INSTRUCTIONS. D Read and follow all labels and the Owner’s Noise from some processes or equipment can damage hearing. Manual carefully before installing, operating, or servicing unit. Read the safety information at D Check for noise level limits exceeding those the beginning of the manual and in each specified by OSHA. -
Page 7: Utilisation
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT UTILISATION SR7(MIG)_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité... -
Page 8: Proposition Californienne 65 Avertissements
D Avoir recours à des écrans protecteurs ou à des rideaux pour D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si protéger les autres contre les rayonnements les éblouissements le niveau de bruit est élevé. et les étincelles ; prévenir toute personne sur les lieux de ne pas D Avertir les personnes à... -
Page 9: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 3-2. Miscellaneous Symbols And Definitions Conventional Amperes Primary Voltage Load Voltage Duty Cycle Degree Of... -
Page 10: Section 4 − Specifications
SECTION 4 − SPECIFICATIONS 4-1. Gun Specifications Model Welding Output Range Electrode Wire Feed Net Weight Wire Diameter Speed Range (Torch Only) Capacity XR- Pistol - Plus Gun 200 A at 100% Duty Cycle .030 To 1/16 in. 50 To 780 ipm 2.5 lb (1.1 kg) (Air Cooled) with 15, 25 or 35 ft... -
Page 11: Section 5 − Installation
SECTION 5 − INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed. 5-1. Equipment Connection Diagram - Single Feeder Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (−) Weld Cable Workpiece... -
Page 12: Equipment Connection Diagram - Dual Feeder
5-2. Equipment Connection Diagram - Dual Feeder Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (−) Weld Cable Workpiece Welding Gun Welding gun assembly shown is for MPa Plus feeder with 14-pin connection. Wire Feeder Gas Hose Gas Cylinder and Regulator (Customer Supplied) Shielding gas pressure not to... -
Page 13: 14-Pin Plug Information For Connecting Wire Feeder To Power Source
5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source Pin* Pin Information Motor Common Motor 0 to +24 volts DC with respect to pin 1 +5 volts DC tachometer power Tachometer ref Tachometer signal Trigger Trigger Wire speed ref. +5 volts DC Wire speed com Wire speed 0 to +5 volts DC with respect to pin 9 Gun sensing resistor with respect to pin 9... -
Page 14: Threading Welding Wire Through Gun
5-5. Threading Welding Wire Through Gun Refer to wire feeder manual for instructions on feeding wire through feeder. Pressure Arm Lever To release drive roll pressure, pull back on pressure arm lever. While pulled back, shift to left onto shoulder to lock into place. Welding wire is electrically live when gun trigger is used to jog wire. -
Page 15: Section 6 − Operation
SECTION 6 − OPERATION 6-1. Gun Controls Trigger Press trigger to energize welding power source contactor applicable), start shielding gas flow, and begin wire feed. Controls at the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released. -
Page 16: Shielding Gas
MILLER Aluminum Protecting Coolant No. 043 809**; Distilled Or Deionized Water OK ° ° Above 32 F (0 Coolant *HF: High Frequency Current ° ° **MILLER coolants protect to -37 F (-38 C) and resist algae growth. Ref. 150755-A OM-248663 Page 12... -
Page 17: Section 7 − Maintenance & Troubleshooting
SECTION 7 − MAINTENANCE & TROUBLESHOOTING Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Clean Replace Replace Damaged Or Damage Tighten Unreadable Gas Hose Weld Labels Terminals Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or Clean Vacuum Inside... -
Page 18: Replacing Head Tube Liner
7-2. Replacing Head Tube Liner Turn Off coolant supply before removing head tube water-cooled gun. The standard head tube liner will accommodate wire diameters from .030-1/16 wire size. When changing wire size, change gun drive roll. Cover Head Tube Remove head tube from gun. Liner Pull liner out of head tube. -
Page 19: Replacing The Liner
7-3. Replacing The Liner Turn Off wire feeder and welding power source. Thumb Screw Cone Guide Collet Guide Brass Guide Cap Unscrew thumb screw. Remove the following items: S Liner conduit assembly from handle. S Cone guide (rear of torch) and col- let guide. -
Page 20: Gun Drive Assembly Maintenance
7-4. Gun Drive Assembly Maintenance Lever Arm Remove pressure on wire by pulling lever arm forward. Pull to left to lock into place. Retract wire onto spool. Drive Roll Use wire brush to clean drive roll. Install drive roll with hex opening down toward shaft hex, and secure with screw. -
Page 21: Troubleshooting Table
7-5. Troubleshooting Table Disconnect power before troubleshooting. Trouble Remedy No wire feed at gun, feeder not operat- Reset circuit breaker at power source. See power source owner’s manual. ing. Check motor or brake solenoid. Replace trigger-switch and test operation. Check trigger-switch wires for continuity. Reset circuit breaker in feeder/control box and check for short in motor leads. -
Page 22: Section 8 − Electrical Diagrams
SECTION 8 − ELECTRICAL DIAGRAMS Ref. 256010-E Figure 8-1. Circuit Diagram For XR - Pistol - Plus Gun OM-248663 Page 18... - Page 23 Notes OM-248663 Page 19...
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Page 24: Section 9 − Parts List
SECTION 9 − PARTS LIST 52 49 67 66 Hardware is common and not available unless listed. T0011-E Figure 9-1. Exploded View Of XR - Pistol - Plus Gun OM-248663 Page 20... - Page 25 Item Part Description Quantity Figure 9-1. Exploded View Of XR - Pistol - Plus Gun ....257353 Kit, Handle XR Pistol Pro/Plus ........
- Page 26 Item Diagram Part Description marking Quantity Figure 9-1. Exploded View Of XR - Pistol - Plus Gun (Continued) ... . . 258474 Kit, Head Tube Assy (Air) AP/PP 180Deg 4In. Lg Cntrfr .
- Page 27 Hardware is common and not available unless listed. T0012 Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Plus Gun Item Part Description Quantity Figure 9-2. (Water) Head Tube Assembly Of XR - Pistol - Plus Gun (Figure 9-1 Item 42) .
- Page 28 Hardware is common and not available unless listed. T0013 Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Plus Gun Item Part Description Quantity Figure 9-3. (Air) Head Tube Assembly Of XR - Pistol - Plus Gun (Figure 9-1 Item 42) .
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Page 29: Section 10 − Parts List Including Consumables
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES Item Number HEAD TUBES A/C 1805 Straight A/C OUTER 1805 Centerfire 258 474 Nozzles (M1366) Centerfire Centerfire W/C OUTER W/C 1805 Straight Contact Tips Diffusers 1805 N − 5818C T − 035AL D − 1AP (M1369) 258 475 T −... - Page 30 Table 10-5. Head Tube Assemblies ... . . 258474 Kit, Head Tube Assy (A) AP/PP 180Deg 4In. Lg Cntrfr ....
- Page 31 Effective January 1, 2019 (Equipment with a serial number preface of MK or newer) 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 Subarc Wire Drive Assemblies below, Miller Electric Mfg.
- Page 32 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 2019 Miller Electric Mfg. LLC 2019−01...
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