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Effective January 1, 2019

(Equipment with a serial number preface of MK 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. LLC, Appleton, Wisconsin, warrants to
authorized distributors 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. Notifications submitted as online warranty claims must
provide detailed descriptions of the fault and troubleshooting steps
taken to diagnose failed parts. Warranty claims that lack the
required information as defined in the Miller Service Operation
Guide (SOG) may be denied by Miller.

Miller shall honor warranty claims on warranted equipment listed
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery
date of the equipment to the end-user purchaser, or 12 months
after the equipment is shipped to a North American distributor, or
18 months after the equipment is shipped to an international
distributor, whichever occurs first.

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 Unless Specified
*

Auto-Darkening  Helmet Lenses (No Labor) (See
Classic Series Exception Below)

*

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

*

Insight Welding Intelligence Products

*

Inverter Power Sources

*

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)

*

Auto-Darkening Weld Masks (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

*

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 (For Housing Multiple Power Sources)

*

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
*

Accessories (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.

4.

Defects caused by accident, unauthorized repair, or
improper testing.

MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at Miller’s
option, either: (1) repair; or (2) replacement; or, if approved in
writing by Miller, (3) the pre-approved 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 use). Products may not be returned
without Miller’s written approval. Return shipment shall be at
customer’s risk and expense.
The above remedies are F.O.B. Appleton, WI, or Miller’s
authorized service facility. Transportation and freight are the
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY, GUARANTY, OR REPRESENTATION,
 INCLUDING 

ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
MILLER.
Some US states do not allow limiting the duration of an implied
warranty or the exclusion of certain damages, so the above
limitations may not apply to you. This warranty provides
specific legal rights, and other rights may be available
depending on your state. In Canada, some provinces provide
additional warranties or remedies, and to the extent the law
prohibits their waiver, the limitations set out above may not
apply. This Limited Warranty provides specific legal rights, and
other rights may be available, but may vary by province.

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.

mil dom warr 2019-01

Summary of Contents for XR-AlumaPro Series

Page 1: ...n Processes Description MIG GMAW Welding OM 227398S 2019 05 Semi Automatic Air Water Cooled MIG GMAW Welding Gun File MIG GMAW 400 Ampere Water Push Pull Welding Gun For product information Owner s Ma...

Page 2: ...roducts continue 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 he...

Page 3: ...er Source Having A 14 Socket Receptacle 8 5 2 Air Cooled Gun Connections 9 5 3 Water Cooled Gun Connections 10 5 4 Millermatic 350P Water Cooled Gun Connections 11 5 5 Threading Welding Wire For Aluma...

Page 4: ...ratus Identification Product Stock Number XR W ALUMA PRO 300003 300004 300265 XR W ALUMA PRO PLUS 300003001 300004001 Council Directives 2014 35 EU Low Voltage 2011 65 EU Restriction of the use of cer...

Page 5: ...ding power source before changing contact tip or gun parts D Keep all covers and handle securely in place FUMES AND GASES can be hazardous D Keep your head out of the fumes D Ventilate area or use bre...

Page 6: ...nd Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org S...

Page 7: ...erre D Ne jamais toucher une lectrode ou des pi ces lectriques sous tension D Remplacer les pistolets ou c bles de soudage qui sont endom mag s us s ou craquel s D Mettre la soudeuse hors tension avan...

Page 8: ...ndard 70 from National Fire Protec tion Association Quincy MA 02169 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Co...

Page 9: ...facility Contact your local recycling office or your local distributor for further information Safe37 2017 04 3 2 Miscellaneous Symbols And Definitions V Volts Alternating Cur rent X Duty Cycle Wire...

Page 10: ...ions Operating Temperature Range Storage Temperature Range 14 to 104 F 10 to 40 C 4 to 131 F 20 to 55 C Temp_2016 07 C Information On Electromagnetic Fields EMF This equipment shall not be used by the...

Page 11: ...verheating NOTICE Exceeding duty cycle can damage unit and void warranty sduty1 5 95 Air Cooled Models Continuous Welding 100 Duty Cycle At 300 Peak Amperage Using 100 Argon Gas w 15 25 Or 35 Foot Gun...

Page 12: ...V Or Constant Current Constant Voltage CC CV Welding Power Source Having A 14 Socket Receptacle Ref 804653 A 805349 A 1 CC CV Or CC CV Welding Power Source 2 24 VAC Contactor Control 14 Pin Plug 3 Neg...

Page 13: ...ntrol Cable Insert plug into Gun Control receptacle and tighten threaded collar 2 Gun Power Pin 3 Gun Bushing 4 Gun Securing Knob 5 Drive Casting Loosen gun securing knob and insert gun power pin thro...

Page 14: ...Gun Bushing 5 Drive Casting Loosen gun securing knob and insert gun power pin through gun bushing until it bottoms against drive casting Tighten knob Close and latch door 6 Gun Coolant In Hose Connec...

Page 15: ...le and tighten threaded collar 4 Water In Hose Connect to coolant supply with supplied coupler and water hose left hand threads 5 Gun Connector Loosen gun securing knob and insert gun connector throug...

Page 16: ...eling Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Set pressure indicator scale to...

Page 17: ...bly out straight 2 Jog Switch Push Jog switch up to feed wire through cable assembly 3 Torque Switch Select proper push feeder torque set ting for wire size being used Use low torque for 030 in 0 8mm...

Page 18: ...1 Tension Arm Open tension arm Thread wire thru inlet guide along drive roll groove and into wire conduit Close tension arm Adjust tension as follows Hold wire tightly to keep it from unraveling 1 1 W...

Page 19: ...ect to pin B D Trigger E Wire speed Ref 9 volts DC H Wire speed com F Wire speed 0 to 9 volts DC with respect to pin H J Gun sensing resistor with respect to pin H I Not used 5 9 Opening Top Cover Of...

Page 20: ...ding Wire Through Gun Ref 804544 B 804545 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 latch wir...

Page 21: ...ise to decrease wire speed Speed control can be rotated more than 3 3 4 turns in both di rections without being damaged 1 2 Ref 804545 B 6 2 Gun Pressure Roll Tension Setting Aluminum series specific...

Page 22: ...table below for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished welding 1 3 2 MILLER Aluminum Protecting Coolant No 043 809 Distilled Or Deionized Water...

Page 23: ...ire 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 gun Close pressure roll assembly and idler rol...

Page 24: ...d tube Insert new liner into head tube install tapered end first and reinstall 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 h...

Page 25: ...ner 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 assembly...

Page 26: ...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 27: ...ozzle 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 de bris Reinstall liner assembly into gu...

Page 28: ...atically Check conduit for wear and obstruction and replace if necessary Check contact tip for correct size and replace if necessary Check pressure roll tension setting see Section 6 2 Check for prope...

Page 29: ...OM 227398 Page 25 SECTION 8 ELECTRICAL DIAGRAMS 228669 B Figure 8 1 Circuit Diagram For XR AlumaPro Gun Notes...

Page 30: ...age 26 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 A Al...

Page 31: ...ir 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 32: ...1 24 227452 Potentiometer Assy 1 25 231443 Screw 006 32x 44 Soc Hd Hex Gr8 Pld Lkg Patch 1 26 134624 Washer Shldr 140id 0 187odx 094t 375odx 031t Nyl 2 27 227439 Drive Roll Assy Idler 645 Od 1 28 2450...

Page 33: ...r local distributor Hardware is common and not available unless listed 804706 A 1 2 3 4 5 10 6 9 7 8 Figure 9 2 Water Head Tube Assembly Of AlumaPro Gun Item No Part No Quantity Description Figure 9 2...

Page 34: ...Short Includes 1 1 198855 Nozzle Copper 5 8 in Orifice Tapered 1 2 206189 Tip Fastip 312 Od 052 And 3 64al Wires 1 3 229670 Diffuser 281 312 Od Fastip 1 8 Tip Rec AlumaPro 1 4 229673 Insulator Outer A...

Page 35: ...ht 1 1 199612 Nozzle Screw On Brass 3 4 in Orifice Straight Heavy Duty 1 1 199613 Nozzle Screw On Brass 5 8 in Orifice 1 1 199614 Nozzle Screw On Brass 5 8 in Orifice Heavy Duty 1 1 199615 Nozzle Scre...

Page 36: ...r Outer Air Short 4 in 1 4 229673 Insulator Outer Air Long 6 in 1 4 230420 Insulator Outer Water Long FasTip 6 in 1 Table 10 6 Head Tube Assemblies 5 231517 Kit Head Tube Assy Water Long 1 5 231518 Ki...

Page 37: ...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 38: ...Notes...

Page 39: ...semblies 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 Pa...

Page 40: ...h 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 Equi...

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