Miller Electric OM-227 398D Owner's Manual

300 Ampere (Air) Push-Pull Welding GunXR - Aluma-Pro (Air And Water-Cooled Guns)ProcessesDescriptionMIG (GMAW) WeldingOM-227 398D2007−12Semi-Automatic

OM-227 398 Page 6SECTION 4 − INSTALLATION. Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to chan

OM-227 398 Page 74-2. XR-Water-Cooled Gun ConnectionsRef. 801 577-A / 805 106-A. Turn on coolant supply beforewelding or gun will be dam-aged.1 Gun Co

OM-227 398 Page 84-3. Millermatic 350P Water Cooled Gun ConnectionsRef. 804 945-A. Turn on coolant supply before weldingor gun will be damaged.1 Coola

OM-227 398 Page 94-4. Threading Welding Wire For Aluma-Pro Gun And Millermatic 350P1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Drive Roll5 Intermedi

OM-227 398 Page 104-5. Threading Welding Wire Through XR-Control FeederRef. 802 193-ATools Needed:211 Cable AssemblyLay cable assembly out straight.2

OM-227 398 Page 114-7. 10-Pin Plug Information10Pin* Pin InformationA Electrode sense leadB Motor CommonEFG TriggerFDJGC Motor 0 to +24 volts dc with

OM-227 398 Page 12! Welding wire is electrically live whengun trigger is used to jog wire.. Refer to Section 4-4 for instructions on feedingwire throu

OM-227 398 Page 13SECTION 5 − OPERATION5-1. Gun Controls1 TriggerPress trigger to energize weldingpower source contactor (ifapplicable), start shieldi

OM-227 398 Page 145-3. Shielding GasRef. 151 666-F / 804 545-B1 Shielding Gas Cylinder2 Valve3 Gun TriggerOpen valve on cylinder just beforewelding.Gu

OM-227 398 Page 155-5. Gun Drive Assembly Maintenance For An XR-Aluma-Pro GunRef. 804 544-B1 Lever ArmUsing lever arm open pressure rollwith bearing a

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-227 398 Page 165-6. Replacing Head Tube Liner In XR-Aluma-Pro GunsRef. 804 544-B. Turn OFF coolant supply beforeremoving head tube onwater-cooled g

OM-227 398 Page 17Ref. 804 546-A5-8. Replacing The Gun Liner On XR-Aluma-Pro Guns! Turn Off welding power source andwire feeder.1 Leather Cover2 Liner

OM-227 398 Page 18SECTION 6 − MAINTENANCE & TROUBLESHOOTING6-1. Routine Maintenance For Aluminum Push/Pull Guns! Disconnect power before maintaini

OM-227 398 Page 19Ref. 804 546-A6-2. Cleaning The Gun Liner On XR-Aluma-Pro Guns! Turn Off welding power sourceand wire feeder.Lay gun cable out strai

OM-227 398 Page 206-3. Troubleshooting Table! Disconnect power before troubleshooting.Trouble RemedyNo wire feed at gun, feeder not operat-ing Check

OM-227 398 Page 21SECTION 7 − ELECTRICAL DIAGRAMS228 669-BFigure 7-1. Circuit Diagram For XR-Aluma-Pro GunNotes

OM-227 398 Page 22SECTION 8 − PARTS LIST. Hardware is common andnot available unless listed.2343231143337353833141539424344451619204681241402136341Fig

OM-227 398 Page 23Ref. 804 511-B610117879277283029726222425231314151617191820215241232DescriptionFigure 8-1. Exploded View Of XR-A Aluma-Pro GunItemNo

OM-227 398 Page 24DescriptionFigure 8-1. Exploded View Of XR-A Aluma-Pro Gun (Continued)ItemNo.PartNo. Quantity10 229 887 Liner, Replacement 15 Ft 1.

OM-227 398 Page 25. Hardware is common andnot available unless listed.804 706-A12345106978Figure 8-2. (Water) Head Tube Assembly Of Aluma-Pro GunItemN

TABLE OF CONTENTSSECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1 . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . .

OM-227 398 Page 26. Hardware is common andnot available unless listed.804 705-A12345786Figure 8-3. (Air) Head Tube Assembly Of Aluma-Pro GunItemNo.Par

OM-227 398 Page 27SECTION 9 − PARTS LIST INCLUDING CONSUMABLESItem Number1234 5Ref. 803 909-A / 805 046-A / 805 047-A / 805 048-AXR-Aluma-Pro4” Head T

OM-227 398 Page 28Table 9-2. Heavy Duty FasTiptContact Tips*2 ♦206 185 .030 in (0.8 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NotesSOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE(METRIC)Specifications Socket or Wrench Size Specifications Socket or

Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/16 in (.188 in)1/4

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

dec_wire_6/05Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating lab

OM-227 398 Page 1SECTION 1 −SAFETY PRECAUTIONS FOR GMAWWELDING GUNS − READ BEFORE USINGSR7_2007−04Protect yourself and others from injury — read and f

OM-227 398 Page 21-3. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it f

OM-227 398 Page 3SECTION 2 − DEFINITIONS1 1.1 1.2 1.33 3.1 3.2 3.34 4.1+22.12.2++56+2.3S-178 936A. Warning! Watch Out! Thereare possible hazards assho

OM-227 398 Page 42-2. Manufacturer’s Rating Label For CE Products Only229 109-A2-3. WEEE Label (For Products Sold Within The EU)Do not discard product

OM-227 398 Page 5SECTION 3 − INTRODUCTION3-1. SpecificationsModel Welding Output Range Electrode Wire Diameter CapacityWire Feed Speed RangeNet Weight