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Effective January 1, 2017

(Equipment with a serial number preface of MH 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 below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective date of
this limited warranty is free of defects in material and workmanship at
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS.

Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
or workmanship. Miller must be notified in writing within thirty (30) days
of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted
as an online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.

Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.

1.

5 Years Parts — 3 Years Labor
*

Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules

2.

3 Years — Parts and Labor
*

Auto-Darkening  Helmet Lenses (Except Classic
Series) (No Labor)

*

Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

*

Inverter Power Sources (Unless Otherwise Stated)

*

Plasma Arc Cutting Power Sources

*

Process Controllers

*

Semi-Automatic and Automatic Wire Feeders

*

Transformer/Rectifier Power Sources

3.

2 Years — Parts and Labor
*

Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)

*

Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series

4.

1 Year — Parts and Labor Unless Specified
*

AugmentedArc and LiveArc Welding Systems

*

Automatic Motion Devices

*

Bernard BTB Air-Cooled MIG Guns (No Labor)

*

CoolBelt and CoolBand Blower Unit (No Labor)

*

Desiccant Air Dryer System

*

External Monitoring Equipment and Sensors

*

Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)

*

RFCS Foot Controls (Except RFCS-RJ45)

*

Fume Extractors − Filtair 130, MWX and SWX Series

*

HF Units

*

ICE/XT Plasma Cutting Torches (No Labor)

*

Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)

*

Load Banks

*

Motor-Driven Guns (except Spoolmate Spoolguns)

*

PAPR Blower Unit (No Labor)

*

Positioners and Controllers

*

Racks

*

Running Gear/Trailers

*

Spot Welders

*

Subarc Wire Drive Assemblies

*

TIG Torches (No Labor)

*

Tregaskiss Guns (No Labor)

*

Water Cooling Systems

*

Wireless Remote Foot/Hand Controls and Receivers

*

Work Stations/Weld Tables (No Labor)

5.

6 Months — Parts
*

Batteries

6.

90 Days — Parts
*

Accessory (Kits)

*

Canvas Covers

*

Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls

*

M-Guns

*

MIG Guns, Subarc (SAW) Torches, and External
Cladding Heads

*

Remote Controls and RFCS-RJ45

*

Replacement Parts (No labor)

*

Spoolmate Spoolguns

Miller’s True Blue

®

 Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2.

Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

miller_warr 2017-01

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.

Summary of Contents for XR-A AlumaPro Plus 15 ft

Page 1: ...h Pull Welding Gun XR AlumaPro Plus Air And Water Cooled Guns CE And Non CE Models Processes Description MIG GMAW Welding OM 245892J 2017 09 Semi Automatic Air Water Cooled MIG GMAW Welding Gun File M...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...5 INSTALLATION 10 5 1 Equipment Connection Diagram Single Feeder 10 5 2 Equipment Connection Diagram Dual Feeder 11 5 3 14 Pin Plug Information For Connecting Wire Feeder To Power Source 12 5 4 Openi...

Page 4: ...us Identification Product Stock Number XR A ALUMA PRO PLUS 300000003 300001003 XR W ALUMA PRO PLUS 300003001 300004001 Council Directives 2006 95 EC Low Voltage 2011 65 EU Restriction of the use of ce...

Page 5: ...ea or use breathing device The recommended way to determine adequate ventilationis to sample for the composition and quantity of fumes and gases to which personnel are exposed D Read and understand th...

Page 6: ...Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Su...

Page 7: ...a zone de travail ou porter un appareil respiratoire Pour d terminer la bonne ventilation il est recommand de proc der un pr l vementpour la composition et la quantit de fum es et de gaz auxquels est...

Page 8: ...bsite www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788...

Page 9: ...tion facility Contact your local recycling office or your local distributor for further information Safe37 2017 04 3 2 Miscellaneous Symbols And Definitions A Amperes V Volts AlternatingCur rent X Dut...

Page 10: ...ng IP3X This equipment is designed for indoor use and is not intended to be used or stored outside IP3X 2014 06 B Temperature Specifications Operating Temperature Range Storage Temperature Range 14 to...

Page 11: ...anty sduty1 5 95 Air Cooled Models CE Air Cooled Models Continuous Welding 60 Duty Cycle At 250 Peak Amperage Using 100 Argon Gas w 15 25 Or 35 Foot Guns 100 Duty Cycle At 300 Peak Amperage Using 100...

Page 12: ...1 Equipment Connection Diagram Single Feeder 1 Welding Power Source 2 Contactor Control Power Cord 3 Positive Weld Cable 4 Negative Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas...

Page 13: ...actor Control Power Cord 3 Positive Weld Cable 4 Negative Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder and Regulator Customer Supplied Shielding gas pressure not to exc...

Page 14: ...l 6 Trigger 7 Trigger 8 Wire speed ref 5 volts DC 9 Wire speed com 10 Wire speed 0 to 5 volts DC with respect to pin 9 11 Gun sensing resistor with respect to pin 9 12 Not used 13 Not used 14 Not used...

Page 15: ...Welding Wire Through Gun Ref 804 544 B 804 545 B Tools Needed Lay gun cable out straight Press Jog switch until about 6 in 152 mm of wire is sticking out end of contact tip Cut off wire Close and lat...

Page 16: ...trol can be rotated more than 3 3 4 turns in both di rections without being damaged 1 2 Ref 804 545 B 6 2 Gun Pressure Roll Tension Setting Aluminum series specific Pressure roll tension setting ensur...

Page 17: ...t In 3 Coolant Out See table below for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished welding 1 MILLER Aluminum Protecting Coolant No 043 809 Distilled...

Page 18: ...ace Retract wire onto spool 2 Drive Roll Use wire brush to clean drive roll Install drive roll with hex opening down toward shaft hex and secure with screw 3 Pressure Roll Thread welding wire through...

Page 19: ...install head tube onto gun A twisting motion may be need ed to feed liner thru head tube NOTICE Be sure head tube is seated and head tube nut is securely tightened before operating gun If head tube nu...

Page 20: ...old liner from gun end see il lustration above Insert new liner into gun end and continue feeding liner through cable assembly until liner is through power pin assembly and is visible Install liner as...

Page 21: ...wer before maintaining n Check Clean l Replace Daily n Head Tube Liner and Drive Casting see Section 6 6 Weekly n Drive Roll Every Spool of Wire Or n Nozzle Contact Tip Gun Casing n Gun Liner see Sect...

Page 22: ...Nozzle Loosen liner lock allen screw located near back of handle to remove liner guide reducer from gun Blow air from power pin end through liner until clean of debris Reinstall liner assembly into g...

Page 23: ...feeder control owner s manual Check operation of welding power source Wire feeds erratically Check conduit for wear and obstruction and replace if necessary Check contact tip for correct size and rep...

Page 24: ...OM 245892 Page 20 SECTION 8 ELECTRICAL DIAGRAMS 244795 B Figure 8 1 Circuit Diagram For XR AlumaPro Plus Gun Notes...

Page 25: ...OM 245892 Page 21 Notes...

Page 26: ...ge 22 SECTION 9 PARTS LIST Hardware is common and not available unless listed 2 3 4 34 33 49 35 39 37 40 35 49 17 41 44 45 46 47 18 21 22 48 10 14 43 42 23 38 36 1 Figure 9 1 Exploded View Of XR Aluma...

Page 27: ...Air Long 1 3 227403 Cover W Spring Plunger Includes 1 187316 Label Pinch Wordless 1 4 227404 Handle Assembly Left Right 1 5 227407 Tube Liner Stainless 1 6 227406 Strain Relief Cable Control 1 7 M1476...

Page 28: ...Drive Roll Knurled 1 32 227408 Guide Inlet 1 33 196177 Hose Water Out 10 In 1 34 191072 Hose Water In 15 Ft 1 34 229892 Hose Water In 25 Ft 1 35 202513 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 2 36 M1...

Page 29: ...ntact Tip 035 0 9mm 1 4 D 1AP Diffuser Centerfire D 1AP 1 5 230420 Insulator Outer Water Long Fastip 1 6 229889 Nut Headtube Rotation Water 1 7 227416 Insulator Ring Inner Rear 1 230970 Kit Replacemen...

Page 30: ...1 8 in 1 2 T 035AL Centerfire Contact Tip 035 0 9mm 1 3 D 1AP Diffuser Centerfire D 1AP 1 4 229673 Insulator Outer Air Long 1 5 227168 Nut Headtube Rotation 1 6 227416 Insulator Ring Inner Rear 1 230...

Page 31: ...14C Nozzle C Fire Large Copper 3 4 in Recess 1 4 in 1 1 3414 HD Centerfire Nozzle Cone 3 4 in Id 1 4 in Recess 1 1 5818 HD Centerfire Nozzle Cone 5 8 in Id 1 8 in Recess 1 1 N HDC HD Centerfire Nozzle...

Page 32: ...Fastip 1 233999 Liner Phos Bronze 030 1 16 Wire Long Aluma Pro 1 Table 10 7 Wire Kit Not Shown 230708 Kit Idler Roll 1 16 062 1 198377 Hardwire Liner Kit 30W For Steel Stainless 1 OPTIONAL All contact...

Page 33: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 34: ...Notes...

Page 35: ...Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable co...

Page 36: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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