Miller Electric
XR A, XR W
manual
OM-1581
Troubleshooting
Specification
Install
Parts list
Electrical Diagrams
Symbol Usage
Wire Feeder Trouble
Maintenance
Pins a & B of PLG5
Replacing Hub Assembly
Page 45
Notes
OM-1581
Page 41
Page 44
Page 46
Image 45
Page 44
Page 46
Contents
Processes
OM-1581137 532Y
Description
File MIG Gmaw
From Miller to You
Table of Contents
Spot Controls Optional
Troubleshooting
Marks a special safety message
Symbol Usage
Arc Welding Hazards
Electric Shock can kill
Welding can cause fire or explosion
ARC Rays can burn eyes and skin
Flying Metal can injure eyes
Buildup of GAS can injure or kill
California Proposition 65 Warnings
Principal Safety Standards
EMF Information
About Pacemakers
UNE Décharge Électrique peut entraîner la mort
LES Fumées ET LES GAZ peuvent être dangereux
Indique un message de sécurité particulier
Incendie ou une explosion
LE Soudage peut provoquer un
DES Particules Volantes peuvent blesser les yeux
DES Pièces Chaudes peuvent provoquer des brûlures graves
LA Chute DE L’APPAREIL peut blesser
Risque D’INCENDIE OU D’EXPLO
’EMPLOI Excessif peut SUR
DES Organes Mobiles peuvent provoquer des blessures
En ce qui concerne les stimulateurs cardiaques
Principales normes de sécurité
Wire Feeder Specifications
− Specifications
Gun Specifications
Duty Cycle And Overheating
− Installation
Constant Voltage CV Weld- ing Power Source Plug
Removing Top Cover Of Pistol Grip Gun
Top Cover Triangular Boss
Push door back into original posi- tion to close
Air-Cooled Gun Connections
Water-Cooled Gun Connections
Regulator
Air-Cooled Feeder Connections
Top View Rear Panel
Water-Cooled Feeder Connections
Return Fitting On
Supply Fitting On Regulator
Voltage Sensing Lead Connections
Reinstall right side panel
11 VAC/Contactor Control Plug Information
Or -4, install 5-pin or
Pins a & B of PLG5
Receptacle on welding power
Source, and install plug onto
Installing Wire Spool
Threading Welding Wire Through Feeder
Coolant Guidelines
Threading Welding Wire Through Gun
Adjusting Wire Feed Starting Speed
− Operation
Safety Equipment
Front Panel Controls Of Feeder Air-Cooled Model Shown
Work And Voltage Sensing Cable Clamps
Jog Switch
Voltage/Wire Speed Switch And Meter Optional
Run-In Speed Control
Power Switch
Spot Controls Optional
Remote Voltage Control Optional
Internal Controls
Flowmeter Optional
Shielding Gas
Gun Controls
Coolant Supply For Water-Cooled Models Only
Sequence Of Gas Metal Arc Welding Gmaw − Continuous Or Spot
Routine Maintenance
− Maintenance & Troubleshooting
Turn Off all power before maintaining
Months
Changing Or Cleaning Gun Drive Roll
Changing Feeder Drive Roll And Wire Inlet Guide
Close pressure roll assembly. Close and latch door
Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns
Changing Gun Contact Tip
Replacing The Liner
Turn Off welding power source and wire feeder
Split End
Drive Roll Collet Nut
Close gun pressure roll assembly and reinstall gun cover
Replacing Hub Assembly
Adjusting Hub Tension
Water Flow Switch Optional For Water-Cooled Models
Overload Protection
Wire Feeder Trouble
Troubleshooting
Reinstall current pick-up tab if applicable see Section
Filter, and clean fittings see Section
Gun Trouble
Circuit Diagram For Wire Feeder
− Electrical Diagrams
Circuit Diagram For Gun
OM-1581
− Parts List
12 13 9 10 17 18 17
45 46
Dia Part Description Quantity Mkgs
CB1
Includes Items
Motor & Wire Drive -1 Item
Panel, Front w/Components Water-Cooled Model Illustrated
Panel, Front w/Components -1 Item
38Fig
Items 24
Includes
PLG20
136
Head Tube Assembly Of Pistol-Grip Gun
Number
− Parts List Including Consumables
Heavy Duty FasTiptContact Tips
Extra Heavy Duty FasTiptContact Tips
Tapered FasTipt Contact Tips
Insulators
Gas Diffusers
Barrel Assemblies
Head Tube Assemblies
Service
Your distributor also gives
Support
Miller Electric Mfg. Co
To locate a Distributor or Service Agency visit
For assistance in filing or settling claims, contact
Your distributor and/or equipment manufacturer’s
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