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. The
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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_Thank 4/05
Page 3
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING1 . . . . . . . .
Miller Electric Mg. Co.Mr. Danilo Fedolfi,
1635 W. Spencer St.Managing Director
Appleton, WI 54914 USAITW Welding Products Italy S.r.l.
Phone: (920) 734-9821Via Privata Iseo 6/E
European Contact Signature:
Declares that the product:XR - Aluma-Pro
This information is provided for units with CE certification (see rating label on unit).
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
conforms to the following Directives and Standards:
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 7: Torches. IC 60974-7 Ed.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_wire_6/05
Page 5
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
Protect yourself and others from injury — read and follow these precautions.
1-1.Symbol Usage
SR7_2007−04
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.
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 unit.
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 Repair or replace worn, damaged, or cracked gun or cable insula-
tion.
D Turn off welding power source before changing contact tip or gun
parts.
D Keep all covers and handle securely in place.
. 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.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use ap-
proved air-supplied respirator.
ARC RAYS can burn eyes and skin.
D Wear welding helmet with correct shade of fil-
ter.
D Wear correct eye and body protection.
D Cover exposed skin with spatter-resistant
clothing.
HOT PARTS can cause severe burns.
D Allow gun to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.
NOISE can damage hearing.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes.
D Ventilate area, or use breathing device.
D Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for material
used.
WELDING can cause fire or explosion.
D Do not weld near flammable material.
D Do not weld on closed containers.
D Watch for fire; keep extinguisher nearby.
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 cause injury.
D Keep hands and body away from gun tip when
trigger is pressed.
OM-227 398 Page 1
Page 6
1-3.EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
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.
OM-227 398 Page 2
Page 7
SECTION 2 − DEFINITIONS
2-1.Warning Label Definitions
ABC
11.11.21.3
2
33.13.23.3
44.1
2.1
2.2
+
56
+
+
2.3
+
S-178 936
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
OM-227 398 Page 3
Page 8
2-2.Manufacturer’s Rating Label For CE Products Only
2-3.WEEE Label (For Products Sold Within The EU)
229 109-A
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.
2-4.Symbols And Definitions
. Some symbols are found only on CE products.
A
IP
I
1
Amperes
Degree Of
Protection
JogOutputTriggerGun
Press To SetIncreaseTrigger Hold OnTrigger Hold Off
PurgeSpot Weld TimePercentRun-In
Burnback Time
Primary Current
Water (Coolant)
Output
V
Hz
U
1
I
2
VoltsAlternating Current
HertzCircuit BreakerWire Feed
Primary Voltage
Rated CurrentLine Connection
Fuse
U
2
Load VoltageRead Instructions
Continuous
Spot Welding
X
Water (Coolant) In-
Duty Cycle
put
OM-227 398 Page 4
Page 9
3-1.Specifications
SECTION 3 − INTRODUCTION
ModelWelding Output RangeElectrode
Wire Diameter
Capacity
XR-Aluma-Pro Gun
(Air Cooled)
XR-Aluma-Pro Gun
(Water Cooled)
300 A at 100% Duty Cycle
with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
400 A at 100% Duty Cycle
with 15, 25 or 35 ft
(4.6 or 7.6 m) gun
.030 To 1/16 in
(0.8 To 1.6 mm)
aluminum wire
.030 To 1/16 in
(0.8 To 1.6 mm)
aluminum wire
. When changing 1/16 in (1.6 mm) wire, kit 230708 must be installed.
3-2.Duty Cycle And Overheating
Air-Cooled Models
100% Duty Cycle At 300 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Wire Feed
Speed Range
70 To 900 ipm
(1.8 To 23 mpm)
70 To 900 ipm
(1.8 To 23 mpm)
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.
Net Weight
(Torch Only)
2.5 lb (1.1 kg)
(less cables)
2.9 lb (1.3 kg)
(less cables)
Continuous Welding
Water-Cooled Models
100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Continuous Welding
sduty1 5/95
OM-227 398 Page 5
Page 10
SECTION 4 − 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.
4-1.Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant
Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle
1 CC, CV Or CC/CV Welding
Power Source
2 24 VAC/Contactor Control
14-Pin Plug
3 Workpiece
1
2
8
4 Voltage Sensing Lead
(Optional)
Connect lead to workpiece for CC
welding only.
5 Gun
6 Wire Feeder
7 24 VAC/Contactor Control
Cord
!Do not use gas pressure
above 50 psi (345 kPa).
8 Gas Cylinder
3
8
6
7
4
5
XR Control
1
5
OM-227 398 Page 6
Millermatic 350P
804 542-B / 804 653-A
Page 11
4-2.XR-Water-Cooled Gun Connections
7
8
Left Side
. Turn on coolant supply before
welding or gun will be damaged.
1 Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
2 Gun Connector
3 Gun Securing Knob
3
2
4
4 Gun Connector Block
Loosen gun securing knob, and
insert gun connector through Wire
opening until it bottoms against
block. Tighten knob. Close and
latch door.
5 Gun (Coolant) “In” Hose
Connect to Water “In” fitting on
feeder (left-hand threads).
6 Gun (Coolant) “Out” Hose
Connect to Water “Out” fitting on
feeder (left-hand threads)
7 Water (Coolant) Output
8 Water (Coolant) Input
9 XR Control (Coolant) Output
10 XR Control (Coolant) Input
Close and latch door.
Tools Needed:
9/16 in
9
10
6
1
5
Ref. 801 577-A / 805 106-A
OM-227 398 Page 7
Page 12
4-3.Millermatic 350P Water Cooled Gun Connections
8
7
6
5
1
2
Ref. 804 945-A
3
Tools Needed:
9/16 in
. Turn on coolant supply before welding
or gun will be damaged.
1 Coolant Supply
2 Millermatic 350P
3 Gun Control Cable
Insert plug into gun control receptacle and
tighten threaded collar.
OM-227 398 Page 8
4
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 through Wire opening until it
bottoms against block. Tighten knob. Close
and latch door.
6 Water Out Hose
Connect to coolant supply with supplied
coupler and water hose (left-hand threads).
7 Coolant “In”
8 Coolant “Out”
Page 13
4-4.Threading Welding Wire For Aluma-Pro Gun And Millermatic 350P
IMPORTANT!
For Aluminum Push−Pull welding.
Thread hub tension nut loosely
218243−A
3/4 in
Tighten to
1/2 lb.
8
Tools Needed:
. Hold wire tightly to keep it
from unraveling.
6 in
(150 mm)
Pull and hold wire; cut off end.
IMPORTANT!
For Aluminum
Push−Pull welding.
Push wire thru guides into gun;
continue to hold wire.
See Section 4-9 for threading welding
wire through Aluma-Pro guns.
Close and tighten pressure
assembly, and let go of wire.
. Set pressure indicator
scale to 1/2 lb.
1
2
1
2
3
4
Pressure
Indicator
Scale
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
3
4
218244−A
OM-227 398 Page 9
Page 14
4-5.Threading Welding Wire Through XR-Control Feeder
Tools Needed:
2
1
1 Cable Assembly
Lay cable assembly out straight.
2 Jog Switch
Push Jog switch up to feed wire through
cable assembly.
Ref. 802 193-A
4-6.Adjusting Tension At Feeder
Tools Needed:
Open tension arm.
. Hold wire tightly to keep
it from unraveling.
6 in
(150 mm)
Pull and hold wire; cut off end.
Proceed to Section 4-9.
OM-227 398 Page 10
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension asfollows: grasp spool with one hand, press Jog switch, and
turn thumb nut clockwise until motor stalls when Jog
switch is pressed. Back thumb nut off slightly.
Ref. 802 193-A
Page 15
4-7.10-Pin Plug Information
F
G
H
10
E
D
J
G
C
I
B
A
Pin*Pin Information
AElectrode sense lead
BMotor Common
GTrigger
CMotor 0 to +24 volts dc with respect to pin B
DTrigger
EWire speed Ref. +9 volts dc
HWire speed com
FWire speed 0 to +9 volts dc with respect to pin H
JGun sensing resistor with respect to pin H
INot used
4-8.Opening Top Cover Of XR-Aluma-Pro 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. 804 544-B
OM-227 398 Page 11
Page 16
4-9.Threading Welding Wire Through Gun
. Refer to Section 4-4 for instructions on feeding
For XR-Aluma-Pro Gun:
!Welding wire is electrically live when
gun trigger is used to jog wire.
wire through feeder.
. Turn OFF coolant supply before threading wire
through gun..
Cut off wire. Close and
latch wire feeder door.
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.
. Verify pressure adjustment
on handle matches the wire
type. See Section 5-2.
Ref. 804 544-B / 804 545-B
OM-227 398 Page 12
Page 17
SECTION 5 − OPERATION
5-1.Gun Controls
1
2
5-2.Gun Pressure Roll Tension Setting
1 Trigger
Press trigger to energize welding
power source contactor (if
applicable), start shielding gas flow,
and begin wire feed.
Switches inside 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 on XR-Control. Gun Wire
Speed Control has 3-3/4 turns of
adjustment from minimum to maximum.
Ref. 804 545-B
Tools Needed:
. 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
1
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.
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.
Ref. 804 545-B
OM-227 398 Page 13
Page 18
5-3.Shielding Gas
2
1
3
5-4.Coolant Supply For Water-Cooled Models Only
1
3
2
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off (see Section
5-1).
Close valve on cylinder when
finished welding.
Ref. 151 666-F / 804 545-B
1 Coolant Supply
2 Coolant “In”
3 Coolant “Out”
See table below for coolant
guidelines.
Turn On coolant supply before
welding.
Turn Off coolant supply when
finished welding.
Application
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
GTAW Or Where
HF* Is Used
MILLER Low
Conductivity Coolant
No. 043 810**
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
MILLER Aluminum Protecting
Coolant No. 043 809**;
Distilled Or Deionized Water OK
Above 32° F (0° C)
Ref. 150 755-A
OM-227 398 Page 14
Page 19
5-5.Gun Drive Assembly Maintenance For An XR-Aluma-Pro Gun
1 Lever Arm
Using lever arm open pressure roll
with bearing as shown.
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.
2
3 Pressure Roll
Thread welding wire through gun.
Close pressure roll assembly and
idler roll (located in XR control box).
Press jog switch until wire is sticking out end of contact tip.
. When changing wire size and
Close top cover.
using an XR control box you
should change the control box
drive roll and idler. See XR
owners manual for details.
Tools Needed:
1
3
5/16 in
Ref. 804 544-B
OM-227 398 Page 15
Page 20
5-6.Replacing Head Tube Liner In XR-Aluma-Pro Guns
3
2
1
Tapered end
. Turn OFF coolant supply before
removing head tube on
water-cooled gun.
The standard head tube liner will accommodate wire diameters from
.030-.035 wire size.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized liner.
1 Head Tube
2 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.
. A twisting motion may be need-
ed to feed liner thru head tube.
. 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.
tact tip is being used. Incorrect size may cause arcing inside tip, poor feedability and
poor arc starting characteristics(see Section 9).
Reinstall nozzle.
2
1
Ref. 804 709-A
OM-227 398 Page 16
Page 21
5-8.Replacing The Gun Liner On XR-Aluma-Pro Guns
1
. Refer To Instructions Below.
Remove Old Liner (Item 2) From Gun End
Install New Liner (Item 2) Into Gun End
67
5
2
4
2
3
Gun End
. Gently pry open
slots to remove
wire collet guide.
. Cut liner flush with
!Turn Off welding power source and
wire feeder.
1 Leather Cover
2 Liner
3 Liner Lock Allen Screw
4 Liner Guide Reducer
5 Wire Guide Cone
6 Wire Collet Guide
7 Power Pin
Lay gun cable out straight.
wire collet guide.
Remove short leather cover to access liner
assembly.
Loosen liner lock allen screw (located near
back of handle) to remove liner guide reducer from gun.
Remove wire guide cone and wire collet
guide from power pin.
Remove old liner from gun end (see illustration above).
Insert new liner into gun end and continue
feeding liner through cable assembly until
Power Pin End
Ref. 804 546-A
liner is through power pin assembly and is
visible.
Install liner assembly into gun and tighten
liner lock allen screw.
Reinstall wire collet guide at power pin and
tighten onto liner.
Cut liner off flush with wire collet guide. Reinstall wire guide cone.
Refer to Owner’s Manual for instructions
on rethreading wire.
OM-227 398 Page 17
Page 22
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1.Routine Maintenance For Aluminum Push/Pull Guns
!Disconnect power
before maintaining.
n = Check~ = Cleanl = Replace
Daily
n~ Head Tube Liner and
Drive Casting
(see Section 5-6)
Weekly
n~ Drive Roll
Every
Spool
of WireOr
Every
3
Months
n~ Nozzle / Contact Tip~ Gun Casingn~ Gun Liner
(see Section 6-2)
l Unreadable Labels~ Weld Terminalsnl Weld Cable
n 14-Pin Cordn Gas Hose and Fittingsn Gun Cable
OM-227 398 Page 18
Page 23
6-2.Cleaning The Gun Liner On XR-Aluma-Pro Guns
1
5
2
4
3
Gun End
!Turn Off welding power source
and wire feeder.
Lay gun cable out straight.
1 Leather Cover
Remove leather cover to access liner as-
sembly.
2 Liner Guide Reducer
3 Liner Lock Allen Head Screw
4 Power Pin
5 Air Nozzle
Power Pin End
Ref. 804 546-A
Loosen liner lock allen head 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 gun and tighten liner lock allen head screw when finished cleaning.
OM-227 398 Page 19
Page 24
6-3.Troubleshooting Table
f
Wire feeds, shielding gas flows, but
See Troubleshooting section in welding power source manual.
Arc varies and welding wire is kinked
PlaceMotor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire on
TroubleRemedy
!Disconnect power before troubleshooting.
No wire feed at gun, feeder not operating. Check motor or brake solenoid.
No wire feed at gun, feeder operating
properly.
Wire feeds, but welding wire is not energized.
Wire feeds erratically.
Wire feeds one speed only.
Reset circuit breaker in feeder/control box. See feeder/control owner’s manual.
Replace trigger-switch and test operation.
Check trigger-switch wires for continuity.
Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s
manual.
Check potentiometer with meter and replace if necessary.
Check motor and potentiometer wires for continuity.
See feeder/control owner’s manual.
Clean and tighten all power connections.
See feeder/control owner’s manual.
Check operation of welding power source.
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 5-2).
Check for proper head tube liner (see Table 9-7).
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
eeder. Welding wire is not energized.
Shielding gas does not flow.
Wire feeds, shielding gas flows, but See Troubleshooting section in welding power source manual.
welding wire is not energized.
Arc varies and welding wire is kinked Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire on
when feeding out gun.
Secure plug from gun control cable into gun control receptacle on feeder.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
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-227 398 Page 24
Page 29
. Hardware is common and
1
not available unless listed.
4
3
2
1
7
9
6
5
8
10
804 706-A
Figure 8-2. (Water) Head Tube Assembly Of Aluma-Pro Gun
Item
No.
Part
No.Quantity
Description
Figure 8-2. (Water) Head Tube Assembly Of Aluma-Pro Gun (Figure 8-1 Item
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-227 398 Page 25
Page 30
. Hardware is common and
not available unless listed.
4
3
2
1
8
7
6
5
804 705-A
Figure 8-3. (Air) Head Tube Assembly Of Aluma-Pro Gun
Item
No.
Part
No.Quantity
Description
Figure 8-3. (Air) Head Tube Assembly Of Aluma-Pro Gun (Figure 8-1 Item 2)
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.
*All contact tips are packaged in bags of 25.
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-227 398 Page 28
Page 33
Notes
SOCKET/WRENCH SELECTION TABLE
(U.S. STANDARD)
SpecificationsSocket or Wrench SizeSpecificationsSocket or Wrench Size
Bolt
Diameter
1/4 in.250 in3/8 in7/16 in6 mm.2362 in10 mm10 mm
5/16 in.3125 in1/2 in9/16 in8 mm.3150 in14 mm14 mm
3/8 in.375 in9/16 in5/8 in10 mm.3937 in17 mm17 mm
7/16 in.4375 in5/8 in3/4 in12 mm.4724 in19 mm19 mm
1/2 in.500 in3/4 in13/16 in14 mm.5512 in22 mm22 mm
9/16 in.5625 in7/8 in7/8 in16 mm.6299 in24 mm24 mm
5/8 in.625 in15/16 in1 in18 mm.7087 in27 mm27 mm
3/4 in.750 in1-1/8 in1-1/8 in22 mm.8661 in32 mm32 mm
7/8 in.875 in1-5/16 in1-5/16 in24 mm.9449 in36 mm36 mm
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.
Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
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.
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
one year 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
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches and Subarc (SAW) Guns
guarantees or warranties expressed or implied.
* Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers
Miller’s True Blue® Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
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.
miller_warr 2007−01
Page 36
Owner’s Record
Please complete and retain with your personal records.
Model NameSerial/Style Number
Purchase Date(Date which equipment was delivered to original customer.)
Distributor
Address
City
StateZip
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
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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.