Miller Electric XR W, XR A Gun Trouble, Reinstall current pick-up tab if applicable see Section

Page 42

B. Gun Trouble

Trouble	Remedy

No weld output; gun/feeder does not	Secure 115 VAC input plug in 115 volts ac receptacle (see Section 4-11).
work.

	Place Power switch on welding power source in the On position.

Erratic weld output.	Tighten and clean all connections.

Pressing gun/feeder trigger does not en-	Secure plug from gun control cable into 10-socket receptacle on wire feeder (see Section 4-6).
ergize weld control; welding wire is not
energized; shielding gas does not flow.

Wire does not feed; burnback in contact	Reinstall current pick-up tab if applicable (see Section 6-2).
tip.

Wire feeds, shielding gas flows, but	Clean or replace drive rolls. See Troubleshooting section in welding power source Owner’s Manual (see
welding wire is not energized.	Sections 6-2and 6-3).

Wire feeds erratically.	Check and correct drive roll pressure (see Section 4-14).

	Clean drive roll or replace drive roll (see Sections 6-2and 6-3).

Gun overheating (water-cooled	Be sure coolant flowrate is at least 1 qt/min (0.95 L/min).
models).

	Corrosion buildup in gun decreasing coolant flowrate. Backflush coolant system, clean coolant system
	filter, and clean fittings (see Section 4-16).

OM-1581 Page 38

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Contents Description OM-1581137 532YProcesses File MIG GmawFrom Miller to You Table of Contents Troubleshooting Spot Controls OptionalArc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer unIncendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures graves’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesGun Specifications − SpecificationsWire Feeder Specifications Duty Cycle And Overheating− Installation Constant Voltage CV Weld- ing Power Source Plug Removing Top Cover Of Pistol Grip Gun Top Cover Triangular BossPush door back into original posi- tion to close Air-Cooled Gun Connections Water-Cooled Gun Connections Air-Cooled Feeder Connections RegulatorReturn Fitting On Water-Cooled Feeder ConnectionsTop View Rear Panel Supply Fitting On RegulatorReinstall right side panel Voltage Sensing Lead Connections11 VAC/Contactor Control Plug Information Receptacle on welding power Pins a & B of PLG5Or -4, install 5-pin or Source, and install plug ontoInstalling Wire Spool Threading Welding Wire Through Feeder Threading Welding Wire Through Gun Coolant GuidelinesAdjusting Wire Feed Starting Speed Front Panel Controls Of Feeder Air-Cooled Model Shown Safety Equipment− Operation Work And Voltage Sensing Cable ClampsJog Switch Voltage/Wire Speed Switch And Meter OptionalRun-In Speed Control Power Switch Spot Controls OptionalRemote Voltage Control Optional Flowmeter Optional Internal ControlsCoolant Supply For Water-Cooled Models Only Gun ControlsShielding Gas Sequence Of Gas Metal Arc Welding Gmaw − Continuous Or SpotTurn Off all power before maintaining − Maintenance & TroubleshootingRoutine Maintenance MonthsChanging Or Cleaning Gun Drive Roll Changing Feeder Drive Roll And Wire Inlet Guide Close pressure roll assembly. Close and latch door Changing Gun Contact Tip Removing Diffuser In Air And Water-Cooled Pistol-Grip GunsSplit End Turn Off welding power source and wire feederReplacing The Liner Drive Roll Collet NutReplacing Hub Assembly Close gun pressure roll assembly and reinstall gun coverAdjusting Hub Tension Water Flow Switch Optional For Water-Cooled ModelsOverload Protection Troubleshooting Wire Feeder TroubleReinstall current pick-up tab if applicable see Section Filter, and clean fittings see SectionGun Trouble − Electrical Diagrams Circuit Diagram For Wire FeederCircuit Diagram For Gun OM-1581 − Parts List 12 13 9 10 17 18 1745 46 Dia Part Description Quantity Mkgs CB1 Motor & Wire Drive -1 Item Includes ItemsPanel, Front w/Components Water-Cooled Model Illustrated Panel, Front w/Components -1 Item 38Fig Items 24Includes PLG20 136 Head Tube Assembly Of Pistol-Grip Gun − Parts List Including Consumables NumberHeavy Duty FasTiptContact Tips Extra Heavy Duty FasTiptContact TipsTapered FasTipt Contact Tips Barrel Assemblies Gas DiffusersInsulators Head Tube AssembliesService Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s