OM-1500-17 218022A January 2004 Processes MIG (GMAW) Welding Description Semi Automatic, Air Cooled, MIG (GMAW) Welding Gun XR™ Python® 25 Ft. 200 Ampere Push-Pull Welding Gun Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Table of Contents SECTION 1 - Safety Precautions - Read Before Using ......................................... i Symbol Usage................................................................................................... i Arc Welding Hazards ........................................................................................ i Additional Symbols For Installation, Operation and Maintenance ................... ii Principle Safety Standards..............................................................
Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). MK MillerProducts, Electric Mfg.Inc. Co. Manufacturer’s Name: 1635 W.Armstrong Spencer Street 16882 Ave.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_7/02 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Marks a special safety message. Means “Note”; not safety related. 1-2.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800–463–6727 or in Toronto 416–747–4044, website: www.csa–international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions A B 1 1.1 2 2.1 3 3.1 4 4.1 1.2 2.2 + 1.3 2.3 3.2 + 5 C 3.3 + + 6 S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.
1 2 3 Read the Owner’s Manual. Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. Do not overtighten drive roll pressure. Tighten only until drive roll will not slip (motor will not stall) on a stationary wire. 2-2. Rating Label For CE Products S/N: 50/60 U1 = 24 V I1 = 5.
2-3. Symbols And Definitions Note Some symbols are found only on CE products.
Thank You For selecting a quality product. We want you to take pride in operating this product...as much pride as we have in bringing the product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Section 3 Installation Technical Specifications Wire Capacity Aluminum and Cored Wire ........................... .030" - 1/16" (0.8 mm - 1.6 mm) Solid and Hard Wire ..................................... .030" - .045" (0.6 mm - 1.2 mm) Wire Speed (At rated feeder input voltage) .............70 - 875 ipm (22.2 mpm) Duty Cycle - 100% (All ratings are using Argon gas) ............ 200 Amps Peak Shipping Weight (approximate) ...................................... 19.29 lbs. (8.29 Kg) Gun weight (less leads)...
causes the wire to literally float friction-free through the wire conduit. The 24VDC gun motor is controlled by a three and three-quarter (3 3/4) turn potentiometer in the gun handle. Controls and Settings Potentiometer The laterally-positioned potentiometer is located in the lower end of the handle, providing up to 875 ipm (22.2 mpm) with 3 3/4 turns. Micro Switch The micro switch assembly consists of a normally open micro switch and solder-attached leads.
2. Align the drive roll removal tool (P/N 931-0100) over the flats of the drive roll (as shown in Figure 2). Hold the gun with one hand or on a table top, with the other hand give the removal tool a quick snapturn in the CLOCKWISE DIRECTION. 3. Once the drive roll is loose, continue to spin drive roll in the clockwise direction to remove the drive roll from the gun. Figure 2 4. Install a new drive roll on the left-hand threaded shaft. The drive roll will self-tighten when it is feeding wire.
Replacement Kits Handle Kit......................................................................................... 005-0699 Left and right handles, screws and drive roll door, as a replacement for all Python® guns. Trigger Kit......................................................................................... 005-0694 Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python® guns. Micro Switch Kit............................................................
WARNING: Do not attempt to weld without the barrel being tightly secured in the gun body, or damage to the barrel or body may result. Barrel Liner The standard Teflon liner in the XR™ Python® barrel is designed for aluminum and other soft wire. A Steel liner is available for steel, cored and other hard wires. Liner Package, Teflon Standard - Aluminum (5 pcs.) ........................ 931-0137 Liner, Spiral Steel - Steel and Hard Wires. ........................................
Check the resistance across pin “F” (wiper) and pin “H”. The resistance should vary from 5K - 0 ohms as the potentiometer is turned. Testing the Micro Switch Using the amphenol connector, check for continuity across pins “D” and “G” when the trigger is pressed. Section 7 Recommended Spare Parts Listed in the table bale is the factory recommendation of the necessary spare parts which should be kept on hand for maintaining proper operation of the XR™ Python® welding gun. Recommended Spare Parts List Qty.
Troubleshooting Table Symptoms No wire feed at gun, feeder not operating, i.e. no slave motor or brake solenoid. No wire feed at gun, feeder operating properly. Wire feeds, but welding wire is not energized. Wire feeds erratically. Wire feeds one speed only. Wire walks out of drive rolls. Cause Circuit breaker in feeder/ control box open. Remedy Reset. Micro-switch defective/not Replace switch. Check being activated. switch for operation. Broken electrical cable.
Section 9 Appendices Diagrams / Parts List XR™ Python® Parts View ........................................................9 XR™ Python® Bill of Material.................................................10 Python® Front Body Parts View ............................................. 11 XR™ Python® Barrel Parts View............................................12 XR™ Barrel Consumables Listing .........................................13 XR™ Python® Power/Gas Connector Parts View..................
XR™ Python® - 25 Ft.
XR™ Python® Owner's Manual - page 10 Qty 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 6 2 1 2 1 1 9 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 328-0012 321-1104 321-0424 320-0084 319-0258 319-0254 303-0096 211-0077 203560 203562 189811 189812 145217 003-2241 003-2240 005-0695 003-2153 005-0701 003-2125 003-2108 005-0694 002-0631 002-0629 Part No.
Python® Front Body Assembly P/N 003-2108 Python® Front Body Assembly No. Qty. Part Number Description 1 1 003-2083 Output Shaft Assembly 2 1 003-2106 Body Assembly 3 1 325-0206 10-24 x 3/8 PH Screw 4 1 333-0082 # 10 Lock Washer 5 1 419-0092 0.29 x 0.047 x 0.32 Comp.
XR™ Python® Barrel Assembly - 60° P/N 003-2240 XR™ Python® 60º Barrel Assembly No. Qty. Part Number Description 1 1 206195* Diffuser, 1/8 Tip Recess 2 1 002-0652 Assy Barrel Bend XR Python 3 1 003-2213 Assy Taper Lock Barrel 4 1 198855* Nozzle, Copper, 5/8" Orifice 5 1 206189* .052 Heavy Duty FasTip 6 4 303-0010 O-Ring, 0.489 ID x 0.629 OD 7 2 303-0094 O-Ring, 0.301 ID x 0.070 WT 8 1 313-0091 Retaining Ring 9 1 261-0157 Barrel Insulator 10 0.66ft.
XR™ Replacement Consumables Item P/N Description 4 176238 4 176240A NOZZLE, spot inside corner 4 176242A NOZZLE, spot outside corner 4 199610 NOZZLE, screw on brass 1/2" orifice 4 199611 NOZZLE, screw on brass 3/4" orifice straight 4 199612 NOZZLE, screw on brass 3/4" orifice straight heavy duty 4 199613 NOZZLE, screw on brass 5/8" orifice 4 199614 NOZZLE, screw on brass 5/8" orifice heavy duty 4 199615 NOZZLE, screw on copper 1/2" orifice 4 199616 NOZZLE, screw on copper 3/4"
XR™ Python® Power/Gas Connector P/N 003-2241 XR™ Python® Power/Gas Connector No. Qty. Part Number Description 1 0.45ft 615-0351 2 2 602172 3 1 321-1104 4 1 202513 Gas Hose Fitting 5 1 202216 Outlet Wire Guide 6 1 193896 Power Pin Assy 7 1 431-1743 8 1 141694 Set Screw, 5/16-18 x 0.37 9 1 137495 Power Weld Fitting 10 2 079974 O-Ring, 0.
XR™ Python® Electrical Schematic/ Connector Pinout Polarizing Key "X" Clocked Amphenol Connector Viewed from back of connector XR™ Python® Owner's Manual - page 15
Safety Warnings XR™ Python® Owner's Manual - page 16
XR™ Python® Owner's Manual - page 17
3 YEAR LIMITED WARRANTY Effective February 1, 2003 Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
