Miller INTELLX WIRE DRIVE ASSEMBLIES Parts Manual
- Type
- Parts Manual
Miller INTELLX WIRE DRIVE ASSEMBLIES are designed to provide precise wire feeding for a variety of welding applications. With their advanced features such as jog/purge switch, 19-pin Ethernet receptacle, and gas valve, these assemblies offer enhanced control and versatility. They are suitable for both single and dual wire drive configurations, making them ideal for a wide range of welding needs. The assemblies include a motor control circuit card with a pre-programmed motor control program, ensuring optimal performance and reliability.
Miller INTELLX WIRE DRIVE ASSEMBLIES are designed to provide precise wire feeding for a variety of welding applications. With their advanced features such as jog/purge switch, 19-pin Ethernet receptacle, and gas valve, these assemblies offer enhanced control and versatility. They are suitable for both single and dual wire drive configurations, making them ideal for a wide range of welding needs. The assemblies include a motor control circuit card with a pre-programmed motor control program, ensuring optimal performance and reliability.
Processes
PM-285491A 2023−08
Intellx/Intellx Dual
Wire Drive Assemblies
Processes
Description
Wire Feeder
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
File: Advanced Manufacturing Systems
™™
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
PARTS MANUAL
Eff w/Serial Number NA116091U
Thru ND365668U
OM-285491 Page 3
Serial No. Prior to ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1-1. Main Assembly (Left)
Quantity
1 S2, PLG3 280005 Switch Assy, Jog/Purge 1.. .. .. .. ..........................................
2 285272 Label, Nameplate Intellx Front 1.. .............. .. ....................................
3 285271 Enclosure, Drive Assy Intellx 1.. .............. .. ......................................
4 275806 Label, Warning Hot Surfaces And Moving Parts 1.. .............. .. .....................
5 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
6 PLG9, RC2 280004 Plugs, W/Leads (Trigger Receptacle) 1.. . . .. ..............................
RC2 048282 Rcpt W/Skts, (Service Kit) 1.......... .... .. ........................................
7 RC1 280119 Receptacle, W/Leads & Plug 19Pin Ethernet (Feeder) 1.. .... .... .. ................
PLG17, PLG18......
8 GS1 226819 Valve, 12VDC 1Way .750−14 Thd 2MM Orf 100PSI 1.. .... .... .. ..................
9 PC1 279350 Circuit Card Assy, Motor Control W/Program 1.. .... .... .. ........................
10 285280 Wrapper/Door Assy, Intellx Drive 1.. .............. .. ..................................
11 274964 Label, Warning General Precautionary (EN/FR/SP) 1.. .............. .. ..................
12 RC3 239737 Receptacle, Banana Jack Blk 10−32 Binding Post 1.. .... .... .. ...................
13 211989 Fitting, W/Screen 1.. .............. .. ................................................
14 134201 Stand−Off Support, PC Card .312/.375W/Post&Lock .43 6.. .............. .. ..............
15 220805 Nut, 750−14 Nps 1.48Hex .41H Nyl (Prior to /NA435600U) 1.. .............. .. ............
15 272186 Nut, 750−14 Nps 1.312Hex .413H Nyl (Eff w/NA435600U) 1... .............. .. ............
16 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
17 Figure 1-3 Drive Assy, Wire 4 Roll W/Tach Rh 1.. ............ .. ................................
18 274925 Label, Warning Falling Boom 1.. .............. .. ......................................
PLG4 280006 Plug, W/Leads (Gas Valve) 1.......... .... .. .......................................
PLG1 280008 Plug, W/Leads (Volt Sense) 1.......... .... .. .......................................
PLG16 286419 Jumper, ROI Power Switch 1......... ... .. .......................................
PLG10, RC20 286425 Jumper, ROI Feeder Motor Polarity Reverse (Not Shown) 1...... .. ............
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-285491 Page 5
Serial No. Prior to ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1−2. Intellx Dual Wire Drive Assembly
Quantity
1 Figure 1-4 Drive Assy, Wire 4 Roll W/Tach Rh 1.. ............ .. ................................
2 Figure 1-3 Drive Assy, Wire S/L 4 Roll W/Tach 1.. ............ .. ................................
3 285262 Panel, Right Side Dual Boom 1.. .............. .. .....................................
4 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
5 275806 Label, Warning Hot Surfaces And Moving Parts 2.. .............. .. .....................
6 285261 Enclosure, Drive Assy Intellx Dual Boom 1.. .............. .. ...........................
7 285266 Wrapper/Door Assy, Intellx Dual Boom 1.. .............. .. .............................
8 GS1, 2 226819 Valve, 12VDC 1Way .750−14 Thd 2MM Orf 100PSI 2.. ... ... .. ..................
9 211989 Fitting, W/Screen 2.. .............. .. ................................................
10 220805 Nut, .750-14 NPS 1.48Hex .41H Nyl 2.. .............. .. ...............................
11RC1, PLG17, 18 280119 Receptacle, W/Leads & Plug 19Pin Ethernet (Feeder) 1.. .. ................
12 S2, PLG3 280005 Switch Assy, Jog/Purge 1.. .. .. .. ..........................................
13 RC2, PLG9 280004 Plugs, W/Leads (Trigger Receptacle) 1.. . . .. ..............................
048282 Rcpt W/Skts, (Service Kit) 1.................... .. ........................................
14 RC4, PLGG6 284095 Plugs, W/Leads (Trigger Rcpt − Dual Right Side) 1.. .. ....................
048282 Rcpt W/Skts, (Service Kit) 1.................... .. ........................................
15 PC1 279350 Circuit Card Assy, Motor Control W/Program 1.. .... .... .. ........................
16 134201 Stand−Off Support,PC Card .312/.375W/Post&Lock .43 1.. .............. .. ..............
17 285265 Label, Nameplate Intellx Dual Rear Boom 1.. .............. .. ..........................
18 RC3 239737 Receptacle, Banana Jack Blk 10−32 Binding Post 1.. .... .... .. ...................
19 285264 Label, Nameplate Intellx Dual Front Boom 1.. .............. .. ..........................
20 274964 Label, Warning General Precautionary (EN/FR/SP) 1.. .............. .. ..................
21 274925 Label, Warning Falling Boom 1.. .............. .. ......................................
PLG4 280006 Plug, W/Leads (Gas Valve) (Not Shown) 1.......... .... .. ...........................
PLG1 280008 Plug, W/Leads (Volt Sense) (Not Shown) 1.......... .... .. ...........................
PLG5 284096 Plug, W/Leads (Gas Valve − Dual Right Side) (Not Shown) 1.......... .... .. ...........
PLG16 286419 Jumper, ROI Power Switch (Not Shown) 1......... ... .. ............................
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-285491 Page 6
Serial No. Prior to ND365668U
.Hardware is common and
not available unless listed.
282450-B
1
2
3
4
5
6
7
8
9
10
11 12 13
14
15
16
19
17
20
21
22
23
24 25
26
27
28
See Table 1-1 For
Drive Roll & Wire Guide Kits
18
Figure 1-3. Drive Assembly, Wire - Left Side
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1-3. Drive Assembly, Wire - Left Side (Figure 1-1 Item 4)
Quantity
1 M1 279222 Motor, Gear 24VDC 146RPM 29:1 Ratio Continuous W/Tach 1... .... ...... .. .........
2 279256 Ftg, Hose Brs Barbed W/Volt Sense Mtg 1... ............... .. ...........................
3 279252 Insulator, Motor Drive (4 Roll) 1... ............... .. .....................................
4 281870 Screw, 010−32x .94 Flathd−Soc Stl Pld (Customized) 2... ............... .. ................
5 281784 Spring, Cprsn .180 Od X .018 Wire X .531 Pld 1... ............... .. ......................
6 279259 Clamp, Power Pin 1... ............... .. ...............................................
7 237188 Lock, Pin Power 1... ............... .. ................................................
8 124778 Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg 1... ............... .. .......................
9 172077 Carrier, Drive Roll Keyed 24 Pitch 1... ............... .. .................................
10 605308 Ring, Rtng Ext .500 Shaft X .035 Thk 1... ............... .. ..............................
11 166072 Spacer, Gear 2... ............... .. ...................................................
12 279262 Button, Lock Guide Intermediate 1... ............... .. ..................................
13 279263 Spring, Cprsn .312 Od X .250 Id Rate 5.2 Lbs/In 2... ............... .. ....................
14 279261 Button, Lock Guide Inlet 1... ............... .. .........................................
15 221030 Guide, Wire Inlet Anti−Wear One Pc (.023 TO 5/64) 1... ............... .. .................
16 056209 Guide, Wire Intermediate 1/16−5/64 1... ............... .. ...............................
17 234073 Pin, Hinge 1... ............... .. .....................................................
18 279167 Housing, Wire Drive 4 Roll (Push Button) 1... ............... .. ...........................
19 279255 Pin, Hinge 2... ............... .. .....................................................
20 279257 Spring, Torsion 2... ............... .. .................................................
21 279179 Lever, Mtg Pressure Gear Front (Front L Side/Rear R Side) 1... ............... .. ..........
22 172075 Carrier, Drive Roll W/Cmpnts 24 Pitch 4... ............... .. .............................
23 252238 Stand−Off, Drive Roll Carrier 2... ............... .. .....................................
OM-285491 Page 7
Serial No. Prior to ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1-3. Drive Assembly, Wire - Left Side (Continued)
Quantity
24 279181 Lever, Mtg Pressure Gear Rear (Rear L Side/Front R Side) 1... ............... .. ...........
25 151828 Pin, Cotter Hair .042 X .750 3... ............... .. ......................................
26 252217 Knob Assy, Tension Adjust 2... ............... .. .......................................
27 281348 Screw, 312−18x .50 Flathd−Phl Stl Pld W/Lkg Patch 2... ............... .. .................
28 092865 Key, Stl .1215/.1230 X .750 1... ............... .. ......................................
*Recommended Spare Parts.
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.
Notes
OM-285491 Page 8
Serial No. Prior to ND365668U
.Hardware is common and
not available unless listed.
285059-B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
18
19
20
21
22
23
24 25
See Table 1-1 For
Drive Roll & Wire Guide Kits
26
27 28
29
30
Figure 1-4. Drive Assembly, Wire - Right Side
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1-4. Drive Assembly, Wire - Right Side (Figure 1-1 Item 5)
Quantity
1 M2 279222 Motor, Gear 24VDC 146RPM 29:1 Ratio Continuous W/Tach 1... .... ...... .. .........
2 092865 Key, Stl .1215/.1230 X .750 1... ............... .. ......................................
3 284197 Insulator, Motor Drive Rh (4 Roll) 1... ............... .. ..................................
4 281870 Screw, 010−32x .94 Flathd−Soc Stl Pld (Customized) 2... ............... .. ................
5 221030 Guide, Wire Inlet Anti−Wear One Pc (.023 TO 5/64) 1... ............... .. .................
6 056209 Guide, Wire Intermediate 1/16−5/64 1... ............... .. ...............................
7 283920 Housing, Wire Drive 4 Roll Push Button − Dual Rh 1... ............... .. ..................
8 279263 Spring, Cprsn .312 Od X .250 Id Rate 5.2 Lbs/In 2... ............... .. ....................
9 279262 Button, Lock Guide Intermediate 1... ............... .. ..................................
10 166072 Spacer, Gear 2... ............... .. ...................................................
11 172075 Carrier, Drive Roll W/Cmpnts 24 Pitch 4... ............... .. .............................
12 605308 Ring, Rtng Ext .500 Shaft X .035 Thk 1... ............... .. ..............................
13 172077 Carrier, Drive Roll Keyed 24 Pitch 1... ............... .. .................................
14 124778 Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg 1... ............... .. .......................
15 279261 Button, Lock Guide Inlet 1... ............... .. .........................................
16 234073 Pin, Hinge 1... ............... .. .....................................................
17 284476 Lock, Pin Power (Dual) 1... ............... .. ..........................................
18 284475 Clamp, Power Pin (Dual) 1... ............... .. .........................................
19 281784 Spring, Cprsn .180 Od X .018 Wire X .531 Pld 1... ............... .. ......................
20 280558 Pin, Cotter Hair .047 X .625 Zinc Pld 1... ............... .. ..............................
21 252238 Stand−Off, Drive Roll Carrier 2... ............... .. .....................................
22 279255 Pin, Hinge 2... ............... .. .....................................................
23 279257 Spring, Torsion 2... ............... .. .................................................
24 279181 Lever, Mtg Pressure Gear Rear (Front L Side/Rear R Side) 1... ............... .. ...........
OM-285491 Page 9
Serial No. Prior to ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 1-4. Drive Assembly, Wire - Right Side (Continued)
Quantity
25 151828 Pin, Cotter Hair .042 X .750 2... ............... .. ......................................
26 252217 Knob Assy, Tension Adjust 2... ............... .. .......................................
27 279179 Lever, Mtg Pressure Gear Front (Rear L Side/Front R Side) 1... ............... .. ..........
28 284351 Insulator, Fitting Gas 1... ............... .. ............................................
29 279256 Ftg, Hose Brs Barbed W/Volt Sense Mtg 1... ............... .. ...........................
30 281348 Screw, 312−18x .50 Flathd−Phl Stl Pld W/Lkg Patch 2... ............... .. .................
*Recommended Spare Parts.
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.
Table 1-1. Drive Roll & Wire Guide Kits (4 Drive Roll)
.Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).
Wire Diameter
Fraction Decimal Metric
.023/.025 in.
.030 in.
.035 in.
.045 in.
.052 in.
1/16 in.
.035 in.
.045 in.
.052 in.
1/16 in.
5/64 in.
.035 in.
.045 in.
.052 in.
1/16 in.
5/64 in.
.045 in.
1/16 in.
5/64 in.
.023/.025 in.
.030 in.
.035 in.
.045 in.
.052 in.
.062 in.
.035 in.
.045 in.
.052 in.
.062 in.
.079 in.
.035 in.
.045 in.
.052 in.
.062 in.
.079 in.
.045 in.
.062 in.
.079 in.
0.6 mm
0.8 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
1.2 mm
1.6 mm
2.0 mm
Kit No.
087132
046780
046781
046782
046783
046784
044750
046785
046786
046787
046788
046792
046793
046794
046795
046796
083319
046800
046801
Drive Roll
Part No. Type
087130
053695
053700
053697
053698
053699
072000
053701
053702
053706
053704
132958
132957
132956
132955
132960
083489
053708
053710
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
V-Knurled
V-Knurled
V-Knurled
V-Knurled
V-Knurled
U-Cogged
U-Cogged
U-Cogged
Wire Guide
Inlet Intermediate
056192
056192
056192
056193
056193
056195
056192
056193
056193
056195
056195
056192
056193
056193
056195
056195
056193
056195
056195
056206
056206
056206
056207
056207
056209
056206
056207
056207
056209
056209
056206
056207
056207
056209
056209
056207
056209
056209
Ref. S-0025-
D
.040 in. .040 in. 1.0 mm 191917 053696 V-Grooved 056192 056206
Notes
Processes
PM-285491A 2023−08
Intellx/Intellx Dual
Wire Drive Assemblies
Processes
Description
Wire Feeder
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
File: Advanced Manufacturing Systems
™™
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
PARTS MANUAL
Eff w/Serial Number ND365668U
OM-285491 Page 13
Eff w/Serial No. ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2-5. Main Assembly (Left)
Quantity
1 S2, PLG3 280005 Switch Assy, Jog/Purge 1.. .. .. .. ..........................................
2 285272 Label, Nameplate Intellx Front 1.. .............. .. ....................................
3 285271 Enclosure, Drive Assy Intellx 1.. .............. .. ......................................
4 294546 Label, Warning Hot Surfaces/Moving Parts Wire Drive 1.. .............. .. ................
5 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
6 PLG9, RC2 280004 Plugs, W/Leads (Trigger Receptacle) 1.. . . .. ..............................
RC2 048282 Rcpt W/Skts, (Service Kit) 1.......... .... .. ........................................
7 RC1 280119 Receptacle, W/Leads & Plug 19Pin Ethernet (Feeder) 1.. .... .... .. ................
PLG17, PLG18......
8 GS1 226819 Valve, 12VDC 1Way .750−14 Thd 2MM Orf 100PSI 1.. .... .... .. ..................
9 PC1 279350 Circuit Card Assy, Motor Control W/Program 1.. .... .... .. ........................
10 285280 Wrapper/Door Assy, Intellx Drive 1.. .............. .. ..................................
11 274964 Label, Warning General Precautionary (EN/FR/SP) 1.. .............. .. ..................
12 RC3 239737 Receptacle, Banana Jack Blk 10−32 Binding Post 1.. .... .... .. ...................
13 211989 Fitting, W/Screen 1.. .............. .. ................................................
14 134201 Stand−Off Support, PC Card .312/.375W/Post&Lock .43 6.. .............. .. ..............
15 220805 Nut, 750−14 Nps 1.48Hex .41H Nyl (Prior to /NA435600U) 1.. .............. .. ............
15 272186 Nut, 750−14 Nps 1.312Hex .413H Nyl (Eff w/NA435600U) 1... .............. .. ............
16 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
17 Figure 2-7 Drive Assy, Wire 4 Roll W/Tach Rh 1.. ............ .. ................................
18 274925 Label, Warning Falling Boom 1.. .............. .. ......................................
19 294550 Label, Wire Drive, Right Side Panel 1.. .............. .. ................................
PLG4 280006 Plug, W/Leads (Gas Valve) 1.......... .... .. .......................................
PLG1 280008 Plug, W/Leads (Volt Sense) 1.......... .... .. .......................................
PLG16 286419 Jumper, ROI Power Switch 1......... ... .. .......................................
PLG10, RC20 286425 Jumper, ROI Feeder Motor Polarity Reverse (Not Shown) 1...... .. ............
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-285491 Page 15
Eff w/Serial No. ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2−2. Intellx Dual Wire Drive Assembly
Quantity
1 Figure 2-8 Drive Assy, Wire 4 Roll W/Tach Rh 1.. ............ .. ................................
2 Figure 2-7 Drive Assy, Wire S/L 4 Roll W/Tach 1.. ............ .. ................................
3 285262 Panel, Right Side Dual Boom 1.. .............. .. .....................................
4 285263 Panel, Side Dual Drive Assy/Boom 1.. .............. .. ................................
5 294546 Label, Warning Hot Surfaces/Moving Parts Wire Drive 2.. .............. .. ................
6 285261 Enclosure, Drive Assy Intellx Dual Boom 1.. .............. .. ...........................
7 285266 Wrapper/Door Assy, Intellx Dual Boom 1.. .............. .. .............................
8 GS1, 2 226819 Valve, 12VDC 1Way .750−14 Thd 2MM Orf 100PSI 2.. ... ... .. ..................
9 211989 Fitting, W/Screen 2.. .............. .. ................................................
10 220805 Nut, .750-14 NPS 1.48Hex .41H Nyl 2.. .............. .. ...............................
11RC1, PLG17, 18 280119 Receptacle, W/Leads & Plug 19Pin Ethernet (Feeder) 1.. .. ................
12 S2, PLG3 280005 Switch Assy, Jog/Purge 1.. .. .. .. ..........................................
13 RC2, PLG9 280004 Plugs, W/Leads (Trigger Receptacle) 1.. . . .. ..............................
048282 Rcpt W/Skts, (Service Kit) 1.................... .. ........................................
14 RC4, PLGG6 284095 Plugs, W/Leads (Trigger Rcpt − Dual Right Side) 1.. .. ....................
048282 Rcpt W/Skts, (Service Kit) 1.................... .. ........................................
15 PC1 279350 Circuit Card Assy, Motor Control W/Program 1.. .... .... .. ........................
16 134201 Stand−Off Support,PC Card .312/.375W/Post&Lock .43 1.. .............. .. ..............
17 285265 Label, Nameplate Intellx Dual Rear Boom 1.. .............. .. ..........................
18 RC3 239737 Receptacle, Banana Jack Blk 10−32 Binding Post 1.. .... .... .. ...................
19 285264 Label, Nameplate Intellx Dual Front Boom 1.. .............. .. ..........................
20 274964 Label, Warning General Precautionary (EN/FR/SP) 1.. .............. .. ..................
21 274925 Label, Warning Falling Boom 1.. .............. .. ......................................
22 294548 Label, Wire Drive, Left Side Panel 1.. .............. .. .................................
23 294550 Label, Wire Drive, Right Side Panel 1.. .............. .. ................................
PLG4 280006 Plug, W/Leads (Gas Valve) (Not Shown) 1.......... .... .. ...........................
PLG1 280008 Plug, W/Leads (Volt Sense) (Not Shown) 1.......... .... .. ...........................
PLG5 284096 Plug, W/Leads (Gas Valve − Dual Right Side) (Not Shown) 1.......... .... .. ...........
PLG16 286419 Jumper, ROI Power Switch (Not Shown) 1......... ... .. ............................
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-285491 Page 16
Eff w/Serial No. ND365668U
.Hardware is common and
not available unless listed.
282450-B
1
2
3
4
5
6
7
8
9
10
11 12 13
14
15
16
19
17
20
21
22
23
24 25
26
27
28
See Table 2-2 For
Drive Roll & Wire Guide Kits
18
Figure 2-7. Drive Assembly, Wire - Left Side
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2-7. Drive Assembly, Wire - Left Side (Figure 2-5 Item 4)
Quantity
1 M1 279222 Motor, Gear 24VDC 146RPM 29:1 Ratio Continuous W/Tach 1... .... ...... .. .........
2 279256 Ftg, Hose Brs Barbed W/Volt Sense Mtg 1... ............... .. ...........................
3 279252 Insulator, Motor Drive (4 Roll) 1... ............... .. .....................................
4 281870 Screw, 010−32x .94 Flathd−Soc Stl Pld (Customized) 2... ............... .. ................
5 281784 Spring, Cprsn .180 Od X .018 Wire X .531 Pld 1... ............... .. ......................
6 279259 Clamp, Power Pin 1... ............... .. ...............................................
7 237188 Lock, Pin Power 1... ............... .. ................................................
8 124778 Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg 1... ............... .. .......................
9 172077 Carrier, Drive Roll Keyed 24 Pitch 1... ............... .. .................................
10 605308 Ring, Rtng Ext .500 Shaft X .035 Thk 1... ............... .. ..............................
11 166072 Spacer, Gear 2... ............... .. ...................................................
12 279262 Button, Lock Guide Intermediate 1... ............... .. ..................................
13 279263 Spring, Cprsn .312 Od X .250 Id Rate 5.2 Lbs/In 2... ............... .. ....................
14 279261 Button, Lock Guide Inlet 1... ............... .. .........................................
15 221030 Guide, Wire Inlet Anti−Wear One Pc (.023 TO 5/64) 1... ............... .. .................
16 056209 Guide, Wire Intermediate 1/16−5/64 1... ............... .. ...............................
17 234073 Pin, Hinge 1... ............... .. .....................................................
18 279167 Housing, Wire Drive 4 Roll (Push Button) 1... ............... .. ...........................
19 279255 Pin, Hinge 2... ............... .. .....................................................
20 279257 Spring, Torsion 2... ............... .. .................................................
21 279179 Lever, Mtg Pressure Gear Front (Front L Side/Rear R Side) 1... ............... .. ..........
22 172075 Carrier, Drive Roll W/Cmpnts 24 Pitch 4... ............... .. .............................
23 252238 Stand−Off, Drive Roll Carrier 2... ............... .. .....................................
OM-285491 Page 17
Eff w/Serial No. ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2-7. Drive Assembly, Wire - Left Side (Continued)
Quantity
24 279181 Lever, Mtg Pressure Gear Rear (Rear L Side/Front R Side) 1... ............... .. ...........
25 151828 Pin, Cotter Hair .042 X .750 3... ............... .. ......................................
26 252217 Knob Assy, Tension Adjust 2... ............... .. .......................................
27 281348 Screw, 312−18x .50 Flathd−Phl Stl Pld W/Lkg Patch 2... ............... .. .................
28 092865 Key, Stl .1215/.1230 X .750 1... ............... .. ......................................
*Recommended Spare Parts.
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.
Notes
OM-285491 Page 18
Eff w/Serial No. ND365668U
.Hardware is common and
not available unless listed.
285059-B
1
2
3
4
5
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7
8
9
10
11
12
13
14
15
17
16
18
19
20
21
22
23
24 25
See Table 2-2 For
Drive Roll & Wire Guide Kits
26
27 28
29
30
Figure 2-8. Drive Assembly, Wire - Right Side
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2-8. Drive Assembly, Wire - Right Side (Figure 2-5 Item 5)
Quantity
1 M2 279222 Motor, Gear 24VDC 146RPM 29:1 Ratio Continuous W/Tach 1... .... ...... .. .........
2 092865 Key, Stl .1215/.1230 X .750 1... ............... .. ......................................
3 284197 Insulator, Motor Drive Rh (4 Roll) 1... ............... .. ..................................
4 281870 Screw, 010−32x .94 Flathd−Soc Stl Pld (Customized) 2... ............... .. ................
5 221030 Guide, Wire Inlet Anti−Wear One Pc (.023 TO 5/64) 1... ............... .. .................
6 056209 Guide, Wire Intermediate 1/16−5/64 1... ............... .. ...............................
7 283920 Housing, Wire Drive 4 Roll Push Button − Dual Rh 1... ............... .. ..................
8 279263 Spring, Cprsn .312 Od X .250 Id Rate 5.2 Lbs/In 2... ............... .. ....................
9 279262 Button, Lock Guide Intermediate 1... ............... .. ..................................
10 166072 Spacer, Gear 2... ............... .. ...................................................
11 172075 Carrier, Drive Roll W/Cmpnts 24 Pitch 4... ............... .. .............................
12 605308 Ring, Rtng Ext .500 Shaft X .035 Thk 1... ............... .. ..............................
13 172077 Carrier, Drive Roll Keyed 24 Pitch 1... ............... .. .................................
14 124778 Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg 1... ............... .. .......................
15 279261 Button, Lock Guide Inlet 1... ............... .. .........................................
16 234073 Pin, Hinge 1... ............... .. .....................................................
17 284476 Lock, Pin Power (Dual) 1... ............... .. ..........................................
18 284475 Clamp, Power Pin (Dual) 1... ............... .. .........................................
19 281784 Spring, Cprsn .180 Od X .018 Wire X .531 Pld 1... ............... .. ......................
20 280558 Pin, Cotter Hair .047 X .625 Zinc Pld 1... ............... .. ..............................
21 252238 Stand−Off, Drive Roll Carrier 2... ............... .. .....................................
22 279255 Pin, Hinge 2... ............... .. .....................................................
23 279257 Spring, Torsion 2... ............... .. .................................................
24 279181 Lever, Mtg Pressure Gear Rear (Front L Side/Rear R Side) 1... ............... .. ...........
OM-285491 Page 19
Eff w/Serial No. ND365668U
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 2-8. Drive Assembly, Wire - Right Side (Continued)
Quantity
25 151828 Pin, Cotter Hair .042 X .750 2... ............... .. ......................................
26 252217 Knob Assy, Tension Adjust 2... ............... .. .......................................
27 279179 Lever, Mtg Pressure Gear Front (Rear L Side/Front R Side) 1... ............... .. ..........
28 284351 Insulator, Fitting Gas 1... ............... .. ............................................
29 279256 Ftg, Hose Brs Barbed W/Volt Sense Mtg 1... ............... .. ...........................
30 281348 Screw, 312−18x .50 Flathd−Phl Stl Pld W/Lkg Patch 2... ............... .. .................
*Recommended Spare Parts.
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.
Table 2-2. Drive Roll & Wire Guide Kits (4 Drive Roll)
.Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).
Wire Diameter
Fraction Decimal Metric
.023/.025 in.
.030 in.
.035 in.
.045 in.
.052 in.
1/16 in.
.035 in.
.045 in.
.052 in.
1/16 in.
5/64 in.
.035 in.
.045 in.
.052 in.
1/16 in.
5/64 in.
.045 in.
1/16 in.
5/64 in.
.023/.025 in.
.030 in.
.035 in.
.045 in.
.052 in.
.062 in.
.035 in.
.045 in.
.052 in.
.062 in.
.079 in.
.035 in.
.045 in.
.052 in.
.062 in.
.079 in.
.045 in.
.062 in.
.079 in.
0.6 mm
0.8 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
1.2 mm
1.6 mm
2.0 mm
Kit No.
087132
046780
046781
046782
046783
046784
044750
046785
046786
046787
046788
046792
046793
046794
046795
046796
083319
046800
046801
Drive Roll
Part No. Type
087130
053695
053700
053697
053698
053699
072000
053701
053702
053706
053704
132958
132957
132956
132955
132960
083489
053708
053710
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
V-Knurled
V-Knurled
V-Knurled
V-Knurled
V-Knurled
U-Cogged
U-Cogged
U-Cogged
Wire Guide
Inlet Intermediate
056192
056192
056192
056193
056193
056195
056192
056193
056193
056195
056195
056192
056193
056193
056195
056195
056193
056195
056195
056206
056206
056206
056207
056207
056209
056206
056207
056207
056209
056209
056206
056207
056207
056209
056209
056207
056209
056209
Ref. S-0025-
D
.040 in. .040 in. 1.0 mm 191917 053696 V-Grooved 056192 056206
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2021 Miller Electric Mfg. LLC 2021−01
Miller Electric Mfg. LLC
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
For International Locations Visit
www.MillerWelds.com
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Always provide Model Name and Serial/Style Number.
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Welding Supplies and Consumables
Options and Accessories
Personal Protective Equipment (PPE)
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Welding Process Handbooks
Contact the Delivering Carrier to:
For Service
Owner’s Record
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.
Contact your Distributor for:
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Register your product at www.millerwelds.com/support/
product−registration
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Miller INTELLX WIRE DRIVE ASSEMBLIES Parts Manual
- Type
- Parts Manual
Miller INTELLX WIRE DRIVE ASSEMBLIES are designed to provide precise wire feeding for a variety of welding applications. With their advanced features such as jog/purge switch, 19-pin Ethernet receptacle, and gas valve, these assemblies offer enhanced control and versatility. They are suitable for both single and dual wire drive configurations, making them ideal for a wide range of welding needs. The assemblies include a motor control circuit card with a pre-programmed motor control program, ensuring optimal performance and reliability.
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