Miller | MK380080T | Owner Manual | Miller XR-ALUMAPRO PLUS User manual

Miller XR-ALUMAPRO PLUS User manual
OM-245892L
2019−05
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air/WaterCooled, MIG (GMAW) Welding
Gun
™
XR - AlumaPro Plus
(Air And Water-Cooled Guns)
CE And Non-CE Models
300 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) Push-Pull Welding Gun
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: MIG (GMAW)
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.
Today, the people that build and sell Miller products 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 help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-3. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-5. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4-2. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
5-1. Equipment Connection Diagram - Single Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
5-2. Equipment Connection Diagram - Dual Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source . . . . . . . . . . . . . . . . . . . . . . . .
10
5-4. Opening Top Cover Of XR-AlumaPro Plus Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
5-5. Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
6-1. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
6-2. Gun Pressure Roll Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
6-3. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
6-4. Coolant Supply For Water-Cooled Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
6-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Plus Gun . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
6-6. Replacing Head Tube Liner In XR-AlumaPro Plus Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6-7. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6-8. Replacing The Gun Liner On XR-AlumaPro Plus Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
7-1. Routine Maintenance For Aluminum Push/Pull Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
7-2. Cleaning The Gun Liner On XR-AlumaPro Plus Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
7-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
XR-W ALUMA-PRO
XR-W ALUMA-PRO PLUS
Stock Number
300003, 300004, 300265
300003001, 300004001
Council Directives:
• 2014/35/EU Low Voltage
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-7:2013 Arc welding equipment – Part 7: Torches
Signatory:
May 21, 2019
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
271425C
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2018-01
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the welding power source Owner’s Manual. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Always wear dry insulating gloves.
D Insulate yourself from work and ground.
D Do not touch live electrode or electrical parts.
D Replace worn, damaged, or cracked guns or cables.
D Turn off welding 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 breathing device. The
recommended way to determine adequate
ventilation is to sample for the composition and quantity of fumes
and gases to which personnel are exposed.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING can cause fire or explosion.
D Do not weld near flammable material.
D Do not weld on containers that have held combustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
D Watch for fire; keep extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in
use.
D Always ventilate confined spaces or use approved air-supplied respirator.
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.
D Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
HOT PARTS can burn.
D Allow gun to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.
OM-245892 Page 1
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Check for noise level limits exceeding those
specified by OSHA.
D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.
WELDING WIRE can injure.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Keep hands and body away from gun tip when
trigger is pressed.
1-3. Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection 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 Compressed Gas Association, 14501 George Carter Way, Suite
103, 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, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit.
EMF fields can interfere with some medical implants, e.g. pacemakers.
Protective measures for persons wearing medical implants have to be
taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding
circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
OM-245892 Page 2
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2018−01_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant
et suivez les directives mentionnées afin d’éviter tout danger.
Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées dans le manuel d’utilisation du poste de soudage. Veuillez
lire et respecter toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
D Porter toujours des gants secs et isolants.
D S’isoler de la pièce et de la terre.
D Ne jamais toucher une électrode ou des pièces
électriques sous tension.
D Remplacer les pistolets ou câbles de soudage qui sont endommagés, usés ou craquelés.
D Mettre la soudeuse hors tension avant de remplacer un bec
contact ou des pièces de pistolet.
D S’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
D Éloigner sa tête des endroits renfermant des
vapeurs.
D Aérer la zone de travail ou porter un appareil respiratoire. Pour déterminer la bonne ventilation, il est recommandé de procéder à un
prélèvement pour la composition et la quantité de fumées et de gaz
auxquels est exposé le personnel.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les net-
toyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
LE SOUDAGE peut causer un incendie ou une explosion.
D Ne pas souder à proximité de matériaux inflammables.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
D Lire et comprendre les fiches de données de sécurité et les
instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
D Quand on n’utilise pas le gaz comprimé de protection, fermer le robinet de la bouteille.
D Assurer toujours la ventilation des zones fermées ou utiliser un
appareil respiratoire avec alimentation en air.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LE RAYONNEMENT DE L’ARC peut
brûler les yeux et la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
OM-245892 Page 3
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si
le niveau de bruit est élevé.
D Avertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Éloigner les mains et le corps de la buse du
pistolet après avoir appuyé sur la gâchette.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
LIRE LES INSTRUCTIONS.
D Laisser refroidir le pistolet avant de le toucher.
D Ne pas toucher d’objets métalliques chauds.
D Abriter les objets métalliques contre tout
contact par les personnes à proximité.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Vérifier si les niveaux de bruit excèdent les limites spécifiées par l’OSHA.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des
produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection 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 Compressed Gas Association, 14501 George Carter Way, Suite
103, 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, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Le courant
issu d’un soudage à l’arc (et de procédés connexes, y compris le
soudage par points, le gougeage, le découpage plasma et les
opérations de chauffage par induction) crée un champ
électromagnétique (CEM) autour du circuit de soudage. Les champs
électromagnétiques produits peuvent causer interférence à certains
implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de
protection pour les porteurs d’implants médicaux doivent être prises:
Limiter par exemple tout accès aux passants ou procéder à une
évaluation des risques individuels pour les soudeurs. Tous les
soudeurs doivent appliquer les procédures suivantes pour minimiser
l’exposition aux CEM provenant du circuit de soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
OM-245892 Page 4
3
Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4
Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5
Connecter la pince sur la pièce aussi près que possible de la
soudure.
6
Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7
Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
3-2. Miscellaneous Symbols And Definitions
A
V
X
Amperes
Circuit Breaker
Volts
Trigger
Alternating Current
Trigger Hold On
Spot Weld Time
U1
I2
Primary Voltage
Rated Current
Duty Cycle
Percent
Wire Feed
U2
Load Voltage
Fuse
IP
Degree Of
Protection
Jog
Gun
Line Connection
Press To Set
Trigger Hold Off
Continuous
Spot Welding
Purge
Run-In
Hz
Hertz
Burnback Time
Read Instructions
Output
Water (Coolant)
Input
Increase
I1
Primary Current
Water (Coolant)
Output
OM-245892 Page 5
SECTION 4 − INTRODUCTION
4-1. Specifications
Model
Welding Output Range
Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
(Torch Only)
XR-A AlumaPro Plus 15 ft (4.7 m)
XR-A AlumaPro Plus 25 ft (7.6 m)
XR-A AlumaPro Plus 35 ft (10.7 m)
300 A at 100% Duty Cycle
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.5 lb (1.1 kg)
(less cables)
(CE And Non CE Models)
XR-W AlumaPro Plus 15 ft (4.7 m)
XR-W AlumaPro Plus 25 ft (7.6 m)
XR-W AlumaPro Plus 35 ft (10.7 m)
400 A at 100% Duty Cycle
.030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.9 lb (1.3 kg)
(less cables)
. When using 1/16 in. (1.6 mm) wire, kit 230708 must be installed.
4-2. Environmental Specifications
A. IP Rating
IP Rating
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 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 general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
Notes
OM-245892 Page 6
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Air-Cooled Models
100% Duty Cycle At 300 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding
Water-Cooled Models (CE)
100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding
sduty1 5/95
Notes
OM-245892 Page 7
SECTION 5 − INSTALLATION
. Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed.
5-1. 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 Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water−
cooled Guns Only
1
9
2
3
4
10
8
5
7
6
246040-A
OM-245892 Page 8
5-2. Equipment Connection Diagram - Dual 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 Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water−
cooled Guns Only
1
9
2
3
4
10
8
5
7
6
245240-A
OM-245892 Page 9
5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source
Pin*
Pin Information
1
Motor 0 to +24 volts DC with respect to pin 2
2
Motor Common
3
+5 volts DC tachometer power
4
Tachometer ref
5
Tachometer signal
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.
*The remaining pins are not used.
5-4. Opening Top Cover Of XR-AlumaPro Plus Gun
1
Top Cover
Squeeze sides of cover and lift up
as shown.
To close cover, pivot cover closed
on gun, and push cover down until
cover locks tight.
1
Ref. 804544-B
OM-245892 Page 10
5-5. Threading Welding Wire Through Gun
Refer to wire feeder manual for instructions on
feeding wire through feeder.
For XR-AlumaPro Plus Gun:
!
Welding wire is electrically live when
gun trigger is used to jog wire.
. Turn OFF coolant supply before threading wire
through gun.
Lay gun cable out straight. Press Jog switch until about 6
in. (152 mm) of wire is sticking out end of contact tip.
. Verify pressure adjustment
on handle matches the wire
type. See Section 6-2.
Cut off wire. Close and
latch wire feeder door.
Tools Needed:
Ref. 804544-B / 804545-B
OM-245892 Page 11
SECTION 6 − OPERATION
6-1. Gun Controls
1
Trigger
Press trigger to energize welding
power
source
contactor
(if
applicable), start shielding gas flow,
and begin wire feed.
Controls at the wire feeder can be set
to provide timed shielding gas
preflow and postflow when trigger is
pressed and released. When this
feature is turned Off, no preflow or
postflow is provided for the welding
operation.
2
Gun Wire Speed Control
Use control to fine adjust wire feed
speed set at the wire feeder. Gun
Wire Speed Control has 3-3/4 turns
of adjustment from minimum to maximum.
Rotate control clockwise to increase
wire speed and counterclockwise to
decrease wire speed.
. Speed
1
control can be rotated
more than 3-3/4 turns in both directions without being damaged.
2
Ref. 804545-B
6-2. Gun Pressure Roll Tension Setting
. Aluminum
series specific Pressure roll tension setting
ensures smooth wire feeding
action.
. Gun Pressure Roll Tension is
factory set to 4XXX.
1
Pressure Roll Adjustment
Screw
Wire tension should be set to 4XXX
for 4000 series aluminum wire.
Rotate Pressure Roll Adjustment
Screw fully counterclockwise until
indicator line on adjustment knob
lines up with indicator line on handle
in the 4XXX position.
1
Wire tension should be set to 5XXX
for 5000 series aluminum and stainless wire.
Rotate Pressure Roll Adjustment
Screw fully clockwise until indicator
line on adjustment knob lines up
with indicator line on handle in the
5XXX position.
. Small
diameter (.035) 5000
series wire may run better on
the 4XXXX setting.
Tools Needed:
Ref. 804545-B
OM-245892 Page 12
6-3. Shielding Gas
1
2
3
Shielding Gas Cylinder
Valve
Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off (see Section
6-1).
2
Close valve on cylinder when
finished welding.
1
3
Ref. 151666-F / 804545-B
6-4. Coolant Supply For Water-Cooled Models Only
. Do not loosen head tube with
cooler running.
1
2
3
Coolant Supply
Coolant “In”
Coolant “Out”
See table below for coolant
guidelines.
Turn On coolant supply before
welding.
1
Turn Off coolant supply when
finished welding.
3
2
Application
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
Requirement of Coolant Supply
Water-Cooled Models Only
MILLER Aluminum Protecting
Coolant No. 043 809*;
Distilled Or Deionized Water OK
Above 32° F (0° C)
Minimum flow rate: 0.13 G/min (0.5 L/min)
Minimum inlet pressure: 40 psi (276 kPa)
Maximum inlet pressure: 70 psi (483 kPa)
Minimum cooling power: 1000 Watt (3410 BTU/hr)
Coolant
*MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Ref. 150755-A
OM-245892 Page 13
6-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Plus Gun
1
Lever Arm
Using lever arm open pressure roll
with bearing as shown. Push forward to lock in place.
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 gun.
Engage feeder drive rolls. Press jog
switch until wire is sticking out end
of contact tip.
. When
changing wire size
change feeder drive rolls and
guides to match wire size and
type. See wire feeder owners
manual for details.
2
Close top cover.
1
3
Tools Needed:
7/64, 1/16 in.
OM-245892 Page 14
3/8 in.
Ref. 804544-B / 805194-A
6-6. Replacing Head Tube Liner In XR-AlumaPro Plus Guns
. Turn OFF coolant supply before
removing head
water-cooled gun.
tube
on
The standard head tube liner
(yellow) will accommodate wire
diameters from 3/64 in.- 1/16 in. wire
size.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized
liner.
3
1
2
2
Head Tube
Head Tube Nut
Loosen head tube nut and remove
head tube from gun.
3
Head Tube Liner
Pull liner out of head tube.
Insert new liner into head tube (install
tapered end first) and reinstall head
tube onto gun.
1
Tapered end
. A twisting motion may be needed 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 nut is not adequately tightened, unwanted arcing may occur
between head tube and gun housing.
Ref. 804544-B
6-7. Changing Gun Contact Tip
1
Nozzle
Unscrew nozzle.
2
Centerfire Contact Tip
Remove contact tip.
Install new contact tip.
NOTICE − Make sure correct size
contact tip is being used. Incorrect
size may cause arcing inside tip,
poor feedability and poor arc starting characteristics(see Section 9).
. Centerfire
contact tips designed for aluminum wire have
AL (Example T-.047AL) as a
designator at the end of the part
number.
Reinstall nozzle.
2
1
Ref. 246347-A
OM-245892 Page 15
6-8. Replacing The Gun Liner On XR-AlumaPro Plus Guns
1
4
2
3
Gun End
. Refer to instructions below.
Remove Old Liner (Item 2) From Gun End
Install New Liner (Item 2) Into Gun End
5
6
2
7
Power Pin End
. Gently pry open
slots to remove
wire collet guide.
. Cut liner flush with
wire collet guide.
Ref. 246348-A
!
Turn Off welding power source and
wire feeder.
Remove short leather cover to access liner
assembly.
liner is through power pin assembly and is
visible.
1
2
3
4
5
6
7
Leather Cover
Liner
Liner Lock Allen Screw
Liner Guide Reducer
Wire Guide Cone
Wire Collet Guide
Power Pin
Loosen liner lock allen screw (located near
back of handle) to remove liner guide reducer from gun.
Install liner assembly into gun and firmly
tighten (do not over tighten) liner lock allen
screw.
Remove wire guide cone and wire collet
guide from power pin.
Reinstall wire collet guide at power pin and
tighten onto liner.
Remove old liner from gun end (see illustration above).
Cut liner off flush with wire collet guide. Reinstall wire guide cone.
Insert new liner into gun end and continue
feeding liner through cable assembly until
See Section 5-5 for instructions on rethreading wire.
Lay gun cable out straight.
OM-245892 Page 16
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance For Aluminum Push/Pull Guns
!
n = Check
~ = Clean
Disconnect power
before maintaining.
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 Section 7-2)
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
n 14-Pin Cord
n Gas Hose and Fittings
n Gun Cable
Every
3
Months
OM-245892 Page 17
7-2. Cleaning The Gun Liner On XR-AlumaPro Plus Guns
!
Turn Off welding power
source and wire feeder.
NOTICE − Clean gun liner before cleaning stainless tube and
inlet guide.
1
2
3
Lay gun cable out straight.
1
Leather Cover
Remove leather cover to access liner assembly.
2
3
4
5
Gun End
Liner Guide Reducer
Liner Lock Allen Screw
Power Pin
Air 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.
5
4
Reinstall liner assembly into
gun and firmly tighten (do not
overtighten) liner lock allen
screw when finished cleaning.
Power Pin End
NOTICE − Do not overtighten
liner lock allen screw.
6
Top Cover
7
Set Screw (Inlet Guide)
8
Inlet Guide
Remove inlet guide. From power pin end, blow air through liner
and stainless tube until free of
debris.
Reinstall inlet guide.
6
7
8
5
4
Power Pin End
Ref. 246348-A / 804544-B
OM-245892 Page 18
7-3. Troubleshooting Table
!
Disconnect power before troubleshooting.
Trouble
Remedy
No wire feed at gun, feeder not operat- Reset circuit breaker at power source. See power source owner’s manual.
ing. Check motor or brake solenoid.
Replace trigger-switch and test operation.
Check trigger-switch wires for continuity.
No wire feed at gun, feeder operating Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s
manual.
properly.
Check potentiometer with meter and replace if necessary.
Check motor and potentiometer wires for continuity.
See feeder/control owner’s manual.
Wire feeds, but welding wire is not Clean and tighten all power connections.
energized.
See 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 replace if necessary.
Check pressure roll tension setting (see Section 6-2).
Check for proper head tube liner (see Table 9-7).
Wire feeds one speed only.
Check potentiometer with meter and replace if necessary.
Check continuity of welding gun wire feed speed potentiometer and replace if necessary.
See feeder/control owner’s manual.
Pressing gun trigger does not energize Secure plug from gun control cable into gun control receptacle on feeder.
feeder. Welding wire is not energized.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Shielding gas does not flow.
Wire feeds, shielding gas flows, but See Troubleshooting section in welding power source manual.
welding wire is not energized.
OM-245892 Page 19
SECTION 8 − ELECTRICAL DIAGRAMS
244795-D
Figure 8-1. Circuit Diagram For XR-AlumaPro Plus Gun
Notes
OM-245892 Page 20
Notes
OM-245892 Page 21
SECTION 9 − PARTS LIST
. Hardware is common and
3
not available unless listed.
4
2
1
34
33
38
49
36
35
37
44
39
40
22
35
48
49
10
17
45
41
46
43
21
47
42
23
18
14
Figure 9-1. Exploded View Of XR AlumaPro Plus Gun
OM-245892 Page 22
19
14
8
17
13
34
18
12
16
20
8
15
23
21
22
6
8
11
5
58
9
7
29
30
8
51
31
24
8
8
25
26
27
26
50
32
52
53
54
56
55
57
Ref. T0046B
28
Item
No.
Part
No.
Description
Quantity
Figure 9-1. Exploded View Of XR AlumaPro Plus Gun
. . . 1 . . . . . . . . . . 245981
. . . 2 . . . . . . . . . . 245979
. . . 3 . . . . . . . . . . 227403
. . . . . . . . . . . . . . . . 187316
. . . 4 . . . . . . . . . . 227404
. . . 5 . . . . . . . . . . 227407
. . . 6 . . . . . . . . . . 227406
. . . 7 . . . . . . . . . . . M1476
. . . 8 . . . . . . . . . . 135126
. . . 9 . . . . . . . . . . 234971
. . . 10 . . . . . . . . . . . M1500
. . . 11 . . . . . . . . . . 189081
. . . 12 . . . . . . . . . . 229887
. . . 12 . . . . . . . . . . 229891
. . Head Tube Assy, Water Cooled (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Head Tube Assy, Air (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, W/Spring Plunger (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Pinch Wordless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle Assembly, Left/Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tube, Liner Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief, Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, C, Retaining 0.1875 Dia Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set # 6−32x .12 Cup Pt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set 250−20X .31 Conept Sch Stl W/Nyl Patch . . . . . . . . . . . . . . . . . . . .
. . Screw, Set 312−18X .31 Conept Sch Stl Pln Nylok . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, Replacement 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
6
1
1
1
1
1
OM-245892 Page 23
Item
No.
Part
No.
Description
Quantity
Figure 9-1. Exploded View Of XR AlumaPro Plus Gun (Continued)
. . . 13 . . . . . . . . . . 227608 . . Reducer, Guide Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 252652 . . Kit, Conduit Monocoil 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 252689 . . Kit, Conduit Monocoil 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 144172 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . 237864 . . Clamp, Hose .375 − .450 Clp Dia Slfttng Green W/Shortened Middle Tab . . . 2
. . . 17 . . . . . . . . . . 134834 . . Hose, Sae .187 Id X .410 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . Order by Feet
. . . 18 . . . . . . . . . . 191052 . . Cable, Power/Water Out 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 228696 . . Cable, Power/Water Out 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 234416 . . Cable Cover Assy, Leather W/Velcro 17 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 234109 . . Kit, Cable Cover Leather W/Velcro 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . 234110 . . Kit, Cable Cover Leather W/Velcro 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . M1531 . . Cable, Power 15 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . M1532 . . Cable, Power 25 Ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 235225 . . Strip, Cop .010 X 1.500 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . 246309 . . Cable, Control 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 244701 . . Cable, Control 25 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . 227466 . . Trigger Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 246354 . . Drive Motor Assy, Replacement AlumaPro Plus Guns . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . ++232483 . . Drive Assy, Replacement Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . ++232484 . . Drive Assy, Replacement Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 226588 . . Screw, 010-32x .37 Btn Hd-Soc Sst Lkg Patch . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 227434 . . 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 . . . . . . . . . . . M1102 . . Guide, Cone Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . 229852 . . Guide, Collet Outlet .030−1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . 079974 . . O−Ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . 193896 . . Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . 187029 . . Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . 203539 . . Fitting, Liner Double Wound Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . 189811 . . Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . 149332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 44 . . . . . . . . . . 189812 . . Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . 227449 . . Jacket, Cable 3 Ft 4 In (Power Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . 203560 . . Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . 246119 . . Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . M1501 . . Ftg, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . 089120 . . Clamp, Hose .375 − .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . 227405 . . Lever, Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . 227420 . . Pin, Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . 191088 . . Ring, Rtng Ext .125 Shaft X .015 Thk E Style . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . 227435 . . Arm, Pressure (Machined) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . 227421 . . Spring, Cprsn .360 Od X .059 Wire X .440 Free . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . 229850 . . Washer, Pressure Arm Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 56 . . . . . . . . . . 229849 . . Shaft, Pressure Arm Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . 229851 . . Nut, Pressure Arm Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . M1634 . . Kit, Cable Jumper Encdr AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
++ Drive assemblies include drive housing, pressure arm, pressure arm pin, pressure arm lever, power block assy,
drive shaft assy, pressure arm shaft, tube liner, O-ring, set screws, and springs.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-245892 Page 24
. Hardware is common and
11
8
not available unless listed.
7
9
10
6
5
4
3
2
1
246350-A
Figure 9-2. (Water) Head Tube Assembly Of AlumaPro Plus Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-2. (Water) Head Tube Assembly Of AlumaPro Plus Gun (Figure 9-1 Item 1)
. . . . . . . . . . . . . . . . 245981
. . . 1 . . . . . . . . . . . . . 3414
. . . 2 . . . . . . . . . . N−HDC
. . . 3 . . . . . . . . . T−035AL
. . . 4 . . . . . . . . . . . D−1AP
. . . 5 . . . . . . . . . . 230420
. . . 6 . . . . . . . . . . 229889
. . . 7 . . . . . . . . . . 227416
. . . . . . . . . . . . . . . . 230970
. . . 8 . . . . . . . . . . 194261
. . . 9 . . . . . . . . . . 210771
. . . 10 . . . . . . . . . . . 191191
. . . 11 . . . . . . . . . . 229431
. . Head Tube Assy, Water Cooled (Long) (Includes) . . . . . . . . . . . . . . . . . . . . . . .
. . . . HD Centerfire Nozzle Cone, 3/4 in. Id 1/4 in. Recess . . . . . . . . . . . . . . . . . . .
. . . . HD Centerfire Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Centerfire Contact Tip .035 (0.9mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diffuser, Centerfire D−1AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Outer Water Long Fastip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Headtube Rotation Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Replacement O-Rings Head Tube Water (Includes) . . . . . . . . . . . . . . . . . .
. . . . . O−Ring, .551 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . O−Ring, 14.99mm Id X 1.27mm Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . .
. . . . . O−Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Liner, Teflon .047−.062 Wire X 8.250 (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
3
1
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-245892 Page 25
7
. Hardware is common and
8
not available unless listed.
6
5
4
3
2
1
246351-A
Figure 9-3. (Air) Head Tube Assembly Of AlumaPro Plus Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-3. (Air) Head Tube Assembly Of AlumaPro Plus Gun (Figure 9-1 Item 2)
. . . . . . . . . . . . . . . . 245979
. . . 1 . . . . . . . . . N−5818C
. . . 2 . . . . . . . . . T−035AL
. . . 3 . . . . . . . . . . . D−1AP
. . . 4 . . . . . . . . . . 229673
. . . 5 . . . . . . . . . . 227168
. . . 6 . . . . . . . . . . 227416
. . . . . . . . . . . . . . . . 230969
. . . 7 . . . . . . . . . . . 191191
. . . 8 . . . . . . . . . . 230242
. . Head Tube Assy, Air (Long) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nozzle, C-Fire Large Copper 5/8 in. Recess 1/8 in. . . . . . . . . . . . . . . . . . . . .
. . . . Centerfire Contact Tip .035 (0.9mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diffuser, Centerfire D−1AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Outer Air (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Headtube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Replacement O-Rings Head Tube Air (Includes) . . . . . . . . . . . . . . . . . . . . .
. . . . . O-Ring, .312 Id X .070 Cs 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Liner, Teflon .047−.062 Wire X Long (Centerfire) . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-245892 Page 26
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES
Item
Number
1
2
3
4
5
XR-AlumaPro Plus
6” Head Tube
Centerfire
Nozzles
Insulators
Air (Long)
(245 979)
Centerfire
Contact Tips
Centerfire
Diffusers
N − 3414C
N − 5818C
T − 035AL
T − 047AL
T − 062AL
Inner Rear
(227 416)
XR-AlumaPro Plus
6” Head Tube
D − 1AP
2 pc (3414 − N-HDC)
(5818)
Outer
Air Long
(229 673)
Water
(245 981)
Outer
Water Long
(230 420)
Ref. 246353-A / 805047-A / 805048-A
Figure 10-1. Consumables Flowchart
Item
No.
Part
No.
Description
Quantity
10-1. Consumables Flowchart
Table 10-1. Centerfire Nozzles
...
...
...
...
...
1
1
1
1
1
. . . . . . . . . N−5818C
. . . . . . . ♦N−3414C
. . . . . . . . . . . . . 3414
. . . . . . . . . . . ♦5818
. . . . . . . . . ♦N−HDC
..
..
..
..
..
Nozzle, C-Fire Large Copper 5/8 in. Recess 1/8 in. . . . . . . . . . . . . . . . . . . . . . .
Nozzle, C-Fire Large Copper 3/4 in. Recess 1/4 in. . . . . . . . . . . . . . . . . . . . . . .
HD Centerfire Nozzle Cone, 3/4 in. Id 1/4 in. Recess . . . . . . . . . . . . . . . . . . . . .
HD Centerfire Nozzle Cone, 5/8 in. Id 1/8 in. Recess . . . . . . . . . . . . . . . . . . . . .
HD Centerfire Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
Table 10-2. Centerfire Contact Tips*
...
...
...
...
...
...
...
2
2
2
2
2
2
2
. . . . . . . . . . ♦T−030
. . . . . . . . . . ♦T−035
. . . . . . . . . T−035AL
. . . . . . . . . . ♦T−045
. . . . . . . . . T−047AL
. . . . . . . . . . ♦T−062
. . . . . . . ♦T−062AL
..
..
..
..
..
..
..
Tip, C−Fire .030 (0.8mm) 1.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, C−Fire .035 (0.9mm) 1.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centerfire Contact Tip .035 (0.9mm) Aluminum Wire . . . . . . . . . . . . . . . . . . . . .
Tip, C−Fire .045 (1.2mm) 1.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centerfire Contact Tip 3/64 in. (1.2mm) Aluminum Wire . . . . . . . . . . . . . . . . . .
Tip, C−Fire 1/16 in. (1.6mm) 1.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centerfire Contact Tip 1/16 in. (1.6 mm) Aluminum Wire . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
Table 10-3. Centerfire Diffusers
. . . 3 . . . . . . . . . . . D−1AP . . Diffuser, Centerfire D−1AP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-4. Insulators
. . . 4 . . . . . . . . . . 227416 . . Insulator, Ring Inner Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 229673 . . Insulator, Outer Air Long (6 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 230420 . . Insulator, Outer Water Long FasTip (6 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-245892 Page 27
Table 10-5. Head Tube Assemblies
. . . 5 . . . . . . . . . . 245981 . . Head Tube Assy Water Cooled (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 245979 . . Head Tube Assy Air Cooled (Long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-6. FasTip Head Tube LIners (Not Shown)
. . . . . . . . . . . . . . . . 229674 . . Liner, Teflon .030−.035 Wire X Long (Fastip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 229431 . . Liner, Teflon .047−.062 Wire X Long (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 tips are packaged in bags of 10.
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.
OM-245892 Page 28
Notes
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Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
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
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01
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