Miller KK215443 Owner's manual

Miller
Brand
Miller
Model
KK215443
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
October
1999
Form:
OM-1
88
689A
Effective
With
Serial
No.
KK21
5443
OWNERS
MANUAL
S-22P8
(per
NSPR
10930)
Constant
Speed
Wire
Feeder
For
GMAW
And
FCAW
Welding
Type
of
Input
Power
Welding
Power
Source
Type
Wire
Feed
Speed
Range
Wire
Diameter
Range
Welding
Circuit
Rating
Overall
Dimensions
Weight
24
Volts
AC
Single
Phase
3.5
Amperes
50/60
Hz
Constant
Voltage
(CV)
DC
With
14-Pin
And
Contactor
Control
75
to
630
ipm
(1.9
To
16
mpm)
~
.023
To
5/64
in
(0.6
To
2
mm)
100
Volts~
500
Amperes,
100%
Duty
Cycle
Length:
19-1/4
in
(489
mm)
Width:
7-7/8
in
(200
mm)
Height:
13-1/2
in
(343
mm)
21
lb
(9.5
kg)
coverom
4/95
'
1999
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
N
N\
N
NN
N
N
N
N
N
Work~ng
as
hard
as
you
-
every
power
sovrce
from
Mtller
~s
backed
by
the
most
hassle
free
warrapty
in
the
business.
N
N
N
N
N
N
N
N
N~N~
Miter
offers
e
Technical
N
Manual
which
prowdas
N
more
detailed
set
ce
and
N
parts
r~lbimallor~
for
yocr
unit
To
obtain
a
1~cMcal
Manual~
contact
vu~
local
N
di5tnbukir
Yaut
disIr,butor~
~
can
also
supply
you
~wth
N
Welding
Process
Manuals
such
as
SMAW
OTAW,
GM4W~
aniU3MAWF
N
N
N
N
N
N
N
N
N
N
N
N
__________
N~
N
i//A
Miller
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
p
IREGISTERED
I
QUALITY
SYSTEM
Miller
is
the
first
welding
equipment
manufacturer
in
the
U.S.A.
to
be
registered
to
the
ISO
9001
Quality
System
Standard.
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
parts
list
will
then
help
you
to
decide
which
exact
part
you
may
need
to
fix
the
problem.
Warranty
and
service
information
for
your
particular
model
are
also
provided.
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
catalog
sheets.
To
locate
your
nearest
distributor
call
1-800-4-A-Miller.
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_4/98
1-1
Symbol
Usage
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
~
Means
Note~
not
safety
related.
1-2
Arc
Welding
Hazards
A
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
followthe
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unIt.
A
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC
SHOCK
can.
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Always
verify
the
supply
ground
-
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
-
replace
cord
immediately
if
damaged
-
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
actions
to
avoid
the
hazards.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
Do
not
connect
more
than
one
electrode
or
work
cable
to
any
single
weld
output
terminal.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
FUMES
AND
GASES
can
be
hazardous
=~u~
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
OM-188
689
Page
1
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.
Wear
awelding
helmetfitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.i
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields
under
your
helmet.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
causethem
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.l
(see
Safety
Standards).
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING
METAL
can
Injure
eyes
Welding,
chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP
OF
GAS
can
injure
or
kill
Shutoff
shielding
gas
supply
when
not
in
use.
Always
ventilate
confined
spaces
or
use
approved
air-supplied
respirator.
HOT
PARTS
can
cause,severe
burns.
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacetkers~
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
NOISE
can
damage
hearing..
Noise
from
some
processes
or
equipment
can
damage
hearing.
Wear
approved
ear
protection
if
noise
level
is
high.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
-
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
ARC
RAYS
can
burn
eyes
and
skin
CYLINDERS
can
explode
If
damaged.
S
.
S
.
OM-i88
689
Page
2
FIRE
OR
EXPLOSION
hazard.
Do
not
install
or
place
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
Do
not
overload
building
wiring
-
be
sure
power
supply
system
is
properly
sized,
rated,
and
protected
to
handle
this
unit.
FALLING
UNIT
can
cause
injury
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
and
support
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
OVERUSE
can
ause
OVERHEATING
Allow
cooling
period;
follow
rated
duty
cycle.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Do
not
block
or
filter
airflow
to
unit.
STATIC
~ESD)
can
damage
PC
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
WELDING
WIRE
can
cause
injury.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
MOVING
PARTS
can
cause
Injury
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
II
F
RADIATION
can
cause
interference
High-frequency
(HF.)
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
ARC
WELDING
can
cause
Interference
Electromagnetic
energy
can
interfere
with
sensitive
electronic
equipment
such
as
computers
and
computer-driven
equipment
such
as
robots.
Be
sure
all
equipment
in
the
welding
area
is
electromagnetically
compatible.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
elec
tronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
14.,..
Principal
Safety
Standards
,:.~::
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
NW.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
SiB,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-3
Additional
Symbols
For
Installation,
Operation,
And
Maintenance
OM-188
689
Page
3
1-5
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Electric
And
Magnetic
Fields
Welding
current,
as
it
flows
through
welding
cables,
will
cause
electro-
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
magnetic
fields.
There
has
been
and
still
is
some
concern
about
such
fields.
However,
after
examining
more
than
500
studies
spanning
17
3.
Do
not
coil
or
drape
cables
around
your
body.
years
of
research,
a
special
blue
ribbon
committee
of
the
National
Research
Council
concluded
that:
The
body
of
evidence,
in
the
4.
Keep
welding
power
source
and
cables
as
far
away
from
opera-
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
tor
as
practical.
frequency
electric
and
magnetic
fields
is
a
human-health
hazard.
However,
studies
are
still
going
forth
and
evidence
continues
to
be
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
examined.
Until
thefinal
conclusions
of
the
research
are
reached,
you
possible.
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
About
Pacemakers:
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Pacemakerwearersconsultyourdoctorfirst.
lfclearedbyyourdoctor,
procedures:
then
following
the
above
procedures
is
recommended.
OM-188
689
Page
4
2-3.
Connecting
Shielding
Gas
And
14-Pin
Plug
2-4.
14-Pin
Plug
Information
24
volts
ac
with
respect
to
socket
G.
Pin
Information
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
Circuit
common
for
24
volts
AC
circuit.
+10
volts
dc
output
to
remote
control
with
respect
to
socket
D.
Remote
control
circuit
common.
0
to
+10
volts
dc
input
command
signal
from
remote
control
with
respect
to
socket
D.
3.
2
1
Gas
Hose
With
Quick
Disconnect
Plug
2
Shielding
Gas
Cylinder
3
Valve
4
Flowmeter
Close
valve
on
cylinder
when
fin
ished
welding.
5
14-Pin
Plug
5
Ref.
ST-SQl
155-Al
Ref.
ST-SQl
131
*The
remaining
pins
are
not
used.
OM-188
689
Page
6
2-6.
Installing
And
Threading
Welding
Wire
Install
wire
spool.
Adjust
tension
screw
so
wire
is
taut
when
wire
feed
stops.
Lay
gun
cable
out
straight.
Open
pressure
assembly,
hold
wire
tightly,
and
cut
off
end.
Push
wire
through
guides
into
gun.
Close
and
tighten
pressure
as
sembly.
Press
JOG
button
until
wire
comes
out
gun.
To
adjust
drive
roll
pressure,
press
gun
trigger
to
feed
wire
against
wood
surface.
Tighten
knob
so
wire
does
not
slip.
Cut
off
wire.
Close
door.
Tighten
1111
Tools
Needed:
_-i:~
9/16
in
OM-188
689
Page
8
3-1.
Controls
SECTION
3-
OPERATION
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
~
This
unit
has
a
fixed
pre
flow
time
of
3
seconds,
arid
a
fixed
posit/ow
time
of
5
seconds.
1
Power
Control
Switch
2
Wire
Speed
Control
3
voltage
Control
4
Jog/Purge
Switch
Push
up
to
momentarily
feed
welding
wire
at
speed
set
on
Wire
Speed
control
without
energizing
welding
circuit
or
shielding
gas
valve.
Push
down
to
momentarily
ener
gize
gas
valve
to
purge
air
from
gun
or
adjust
gas
regulator.
3
4
4-1.
Routine
Maintenance
Ref.
ST-801
756
OM-188
689
Page
9
4-2.
Overload
Protection
h~WHd
Trouble
Remedy
Wire
does
not
feed,
unit
completely
in-
operative.
Turn
Power
switch
On.
Check
fuse
Fl
and
replace
if
necessary
(see
Section
4-2).
Check
14-pin
plug
PLG2
connections.
Check
input
power.
Wire
does
not
feed.
Check
circuit
breaker
CB1
and
fuse
Fl.
(see
Section
4-2).
Check
gun
trigger
connection
at
wire
feeder.
Check
gun
trigger
leads
and
trigger
switch.
See
gun
Own
ers
Manual.
Have
Factory
Authorized
Service
Agent
check
drive
motor
and
control
board
PCi.
Wire
feeds
erratically.
Readlust
hub
tension
and
drive
roll
pressure
(see
Section
2-6).
Use
correct
size
drive
roll
(see
Parts
Listing).
Clean
or
replace
dirty
or
worn
drive
roll
(see
Section
2-5).
Remove
weld
spatter
around
nozzle
opening.
Replace
contact
tip
or
liner.
See
gun
Owners
Manual.
Have
Factory
Authorized
Service
Agent
check
drive
motor
and
control
board
PCi.
Wire
feeds
when
Jog
switch
is
pressed
but
not
when
gun
trigger
is
pressed.
Check
gun
trigger
connection
at
wire
feeder.
Check
gun
trigger
leads
and
trigger
switch.
See
gun
Own-
ers
Manual.
Wire
feeds
as
soon
as
power
is
applied.
Check
gun
trigger.
See
gun
Owners
Manual.
Wire
does
not
feed
until
trigger
is
pressed
but
continues
to
feed
after
trig
ger
is
released.
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
valve
rattles
loudly
and
wire
feeds
slowly
or
erratically.
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
does
not
flow;
wire
feeds.
Check
gas
valve.
OM-188
689
Page
10
4-3.
Troubleshooting
M
C~
I~I
C)
~
oOrl
rl
SECTION
5-
ELECTRICAL
DIAGRAM
W
(n~
0
Figure
5-1.
Circuit
Diagram
For
Wire
Feeder
With
Options
188
688-A
0
0
0
-v
f-fl
C)
C)
-J
C)
t
w
AA
C) C)
C)
~
~
Of
(~
~
C)C)C)
r
1r-
C)C)C)
0
0
>C)
DZ
0
-o
C-)
C)
C)
C)
C)
01
U,
C)
0
C)
-k
C.)
x
Of
C)
C)
C.)
Of
C)
C)
8~
ZC)
P10)
0
z
OM-180
226
Page
11
0
LI~
th
a)
.0
8)
Ii)
U)
SECTION
6-
PARTS
LIST
0
(~1
0)
C
C
C
Co
C
U,
/
/
/
/
U)
/
Co
LI)
U,
(0
(8
a)
0
a)
ł
0
ci)
>
0
(0
0T
Parts
in
actual
unit
are
not
a/l
shown
in
this
illustration.
Figure
6-1.
Main
Assembly
802 054-A
OM-188
689
Page
12
Description
Quantity
Figure
6-1.
Main
Assembly
010909
..
NUT,375-16.56hexstlpldstopnut
1
602
243
..
WASHER,
flat
sti
std
.375
2
073
355
..
SPRING,
cprsn
.625
OD
x
.093
wire
1
111
998
..
PIN,
cotter
1
111
929
..
HUB,
spool
1
153390
..
HOUSING
1
116
964
..
CLAMP,
cable
strain
relief
1
120
032
..
CABLE,
port
No.
18
6/c
(order
by
ft)
2ft
115
093
..
CONNECTOR
&
SOCKETS
1
010
916
..
CONNECTOR,
clamp
cable
.750
1
011
310
..
CIRCUIT
BREAKER,
man
reset
1P
3A250V
1
*011
116
..
FUSE,
mintr
gI
slo-blo
7A
1
046
432
..
HOLDER,
fuse
mintr
.250
x
1.250
panel
mtg
1
PANEL,
center
1
WASHER,
shldr
nyl
.625
OD
x
.203
ID
x
.3l2dia
shldr
4
BRACKET,
mtg
valve
gas
1
VALVE,
24VAC
2
way
custom
port
1/8
orf
1
CASE,
control/feeder
1
CATCH,
link-lock
2
BRACKET,
gun
holder
1
INSULATOR,
gun
holder
1
WASHER,
spring
grip
locking
for
.750
shaft
1
CABLE,
port
No.
18
2/c
(order
by
ft)
3ft
CONNECTOR,
tw
1k
2p2w
1
HINGE
1
COVER,
control
feeder
1
LABEL,
warning
general
precautionary
1
LABEL,
warning
electric
shock
1
SWITCH,
rocker
SPST
1OA
25OVAC
1
KNOB,
pointer
2
NAMEPLATE
1
PANEL,
front
1
50
073
562
..
POTENTIOMETER,
C
sltd
sft
1/T
2W
10K
ohm
2
SWITCH,
tgl
SPIT
6A
125VAC
1
COVER,
components
1
PLATE,
keeper
link-lock
2
INSULATION,
motor
1
HOSE,
SAE
.187
ID
x
.410
OD
1
FITTING,
brs
barbed
M
3/l6tbg
x
.250-20
1
WASHER,
flatstl
SAE
.312
1
WASHER,
lock
.380
ID
x
.691
OD
1
KNOB,
T
2.000
bar
w/.312-18
stud
1.500
Ig
1
WASHER,
fIat
.438
ID
x
1.000
OD
x
.083
thk
1
PIN,
cotter
hair
.054x.750
2
PIN,
hinge
1
LEVER,
mtg
pressure
gear
1
SPACER,
gear
1
SCREW,
thumb
stl
.250-20
x
.500
pld
1
CARRIER,
drive
roll
w/components
24
pitch
1
SCREW,
.250-20
x
1.25
sochd-hex
gr
8
1
WASHER,
spring
stl
.500
2
SCREW,
.250-20
x
.500
sochd-hex
gr
8
1
CARRIER,
drive
roll
w/components
keyed
24
pitch
1
KEY,
stl
.1215/.1230
x
.750
1
Item
Dia.
Part
No.
Mkgs.
No.
1....
2....
3....
4....
5....
6....
7....
8....
9....
10
..PLG2..
PLG
100
...CB1...
12
11
Fl
13
1207670010947
14
128673
15
126310
16
GS1
125785
17
1213430010860
18
089572
090102
19
090099
20
044800
21
049455
22
RC2
028114
..23
111694
24
+1213410010947
134464
090439
..25
Si
111997
26
097922
27
197165
28
1207640010947
..29
Ri,
..30
S2
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
134
846
121
342
089
573
089
556
125
473
144
172
602
240
602
213
079
772
602
243
151
828
089
555
166
338
166
072
054
263
172
075
602 009
079
625
121
271
172
076
092
865
OM-188
689
Page
13
50
51
52
53
54
55
56
57
.58
MI.
59
60
.61
Cl
62
..63
PCi
PLG3
PLG1,PLG100
PLG4
PLG2O,
22
PLG23,
RC2O
PLG24
PLG25
RC21,PLG1O1
010
224
601
964
092 237
089
477
085
244
089
562
601
964
602 213
160
816
095
564
095 565
081
895
087111
177
360
134
201
176
286
115
092
115
093
115 091
115
094
115
090
130
203
135
561
134
460
600
322
010
467
197
714
134
834
056
851
138
465
126
368
1259680010930
087318
090102
Description
Quantity
Figure
6-1.
Main
Assembly
(Continued)
1
1
1
1
1
1
1
1
1
1
1
8
1
1
4
1
1
2
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*Recommended
Spare
Parts.
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Part
No.
Mkgs.
No.
PIN,
spring
cs
.187x
1.000
SCREW,
.375-16
x
.75
hex
hd
KNOB,
adj
tension
SPRING,
cprsn
.770
OD
x
.100
wire
WASHER,
cupped
stl
.328
ID
FASTENER,
pinned
SCREW,
cap
stl
hexhd
.375-16
x
.750
WASHER,
lock
stl
split
.375
MOTOR,
24VDC
2.2A
114
RPM
(consisting
of)
BRUSH,
motor
carbon
CAP,
brush
motor
NUT,
well
10-32
blind
fastener
CLAMP,
capacitor
1.375
dia
clip
CAPACITOR,
elctlt
2000uf
45VDC
STAND-OFF
SUPPORT,
PC
card
.312/.375
CIRCUIT
CARD,
motor
control
HOUSING
PLUG
&
SOCKETS
HOUSING
PLUG
&
SOCKETS
HOUSING
PLUG
&
SOCKETS
HOUSING
PLUG
&
SOCKETS
HOUSING
PLUG
&
PINS
HOUSING
PLUG
&
SOCKETS
HOUSING
PLUG
&
PINS
131
059
..
HOUSING
PLUG
&
PINS
COVER,
PC
card
64
1116920010947.
Additional Parts
Not
In
Figure
6-1:
113750
114657
115510
1
1
114
655
..
CONN,
rect
mini
045
6
skt
2
row
plug
(included
in
Service
Kit
115
093)
CONN,
rect
mini
045
4skt
2row
plug
(included
in
Service
Kit
115
094)
CONN,
rect
mini
045
4pm
2row
rcpt
(included
in
Service
Kit
115
090)
CON
N,
rect
mini
045
6pm
2row
rcpt
(included
in
Service
Kit
131
059)
CON
N,
tw
1k
insul
male
(dinse
type)
CABLE,
weld
cop
strd
no
2/0
CON
N,
clamp
cable
1.250
FTG,
hose
hansen
quick-disconnect
HOSE,
SAE
.187
id
x
.410
od
FTG,
hose
brs
barbed
nipple
3/16
BRACKET,
mtg
component
STAND-OFF
SUPPORT,
pc
card
no
6
screw
w/post&lock
.
098
691
..
STAND-OFF,
no
6-32
x
.500
Ig
.250
hex
stl
CIRCUIT
CARD
ASSY,
timer
CLAMP,
stl
cush
1.000
dia
x
.406
mtg
hole
BRACKET,
gun
holder
OM-188
689
Page
14
Table
6-1.
Drive
Roll
And
Wire
Guide
Kits
N
OTE
~
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
.
Kit
No.
Drive
Roll
Inlet
Wire
Guide
Part
No.
Type
Fraction
Decimal
Metric
.023/.025
in.
.023/025
in.
0.6
mm
087
131
087
130
V-Grooved
056
192
.030
in.
.030
in.
0.8
mm
079
594
053 695
V-Grooved
056
192
.035
in.
.035
in.
0.9
mm
079 595
053
700
V-Grooved
056
192
.045
in.
.045
in.
1.2
mm
079
596
053
697
V-Grooved
056
193
.052
in.
.052
in.
1.3
mm
079
597
053
698
V-Grooved
056
193
1/16
in.
.062
in.
1.6mm
079598
053
699
V-Grooved
056
195
.035
in.
.035
in.
0.9
mm
044749 072000
U-Grooved
056192
.045
in.
.045
in.
1.2
mm
079599
053701
U-Grooved
056193
.052
in.
.052
in.
1.3
mm
079
600
053
702
U-Grooved
056
193
1/16
in.
.062
in.
1.6
mm
079
601
053
706
U-Grooved
056
195
5/64
in.
.079
in.
2.0
mm
079
602 053 704
U-Grooved
056
195
.035
in.
.035
in.
0.9
mm
079 606
132
958
V-Knurled
056
192
.045
in.
.045
in.
1.2mm
079
607
132
957
V-Knurled
056
193
.052
in.
.052
in.
1.3mm
079 608
132
956
V-Knurled
056
193
1/16
in.
.062
in.
1.6mm
079 609
132
955
V-Knurled
056
195
.068-.072
in.
.068-.072
in.
1.8mm
089 984
132
959
V-Knurled
056
195
5/64
in.
.079in.
2.0mm
079610
132960
V-Knurled
056195
.045
in.
.045
in.
1.2mm
083
318
083
489
U-Cogged
056
193
.052
in.
.052
in.
1.3mm
083
317
083
490
U-Cogged
056
193
1/16
in.
.062
in.
1.6mm
079 614 053
708
U-Cogged
056
195
5/64
in.
.079
in.
2.0mm
079615
053710
U-Cogged
056195
S-O1
57-C
OM-188
689
Page
15
Notes
OM-188
689
Page
16
Miller
__________________
SERVICE
TRAINING
FROM
MILLER
ELECTRIC
-
These
Service
Videos
will
help
you
learn
about
main
tenance,
troubleshooting,
and
servicing
specific
Miller
equipment.
Also,
if
you
are
a
Miller
Certified
Service
Technician,
these
videos
can
help
you
recertify.
Passing
the
included
test
will
earn
five
points
towards
the
forty
points
needed.
You
will
find
each
of
these
professionally
produced
videos
to
be
very
informative
and
a
valuable
part
of
your
Service
Video
Library.
U
XMT
304
Video
Kit
U
(#197
018)
324-1035
$86.00
U
Additional
XMT
304
Test
Sheet
U
(#197
019)
324-1008
$3.00
1j
S-62
&
S-64
Series
Video
Kit
U
(#197
012)
324-1030
$86.00
I~
Additional
S-62
&
S-64
Test
Sheet
U
(#197
014)
324-1016
$3.00
U
S-MM
Video
Kit
U
(#197
015)
324-1031
$86.00
U
Additional
S-MM
Test
Sheet
(#197
017)
324-1017
$3.00
Payment
Information
Check
or
Money
Order
Send
check
or
money
order
payable
to:
Neenah
Printing
Attn:
Literature
Distribution
Center
P.O.
Box
506
Neenah,
WI
54957-0506
Purchase
Order
________________
Mastercard
Visa
Name
of
Card
holder
__________________________________________________
Account
#
__________________________________
Exp.
Date
_________
Cardholders
signature
To
Order
call
920-751-2120
or
Fax
920-751-2121
Distributor
Name
SERVICE
VIDEOS
Feeder
Series
Package
(2
videos
-
S-62&
S-54
&
60M)
(#197
006)
324-1009
$126.00
Bobcat
225
NT
Video
Kit
(#197
007)
324-1014
$86.00
Additional
Bobcat
225
NT
Test
Sheet
(#197
009)
324-1018
$3.00
Deltaweld
452
Video
Kit
(#197
010)
324-1032
$86.00
Additional
Deltaweld
Test
Sheet
(#197
011)
324-1019
$3.00
Customer
#
Miller
WELDING
EQUIPMENT
SERVICE
ENGINEERING
U
Welding
Equipment
Service
Engineering
Training
Course
(Includes
text,
videotape,
exams,
and
registered
answer
card.)
(#145
870)
$60.00
U
Additional
Text
(Includes
text
and
registered
answer
card.)
(#145
871)
$35.00
Payment
Information
Check
or
Money
Order
Send
check
or
money
order
payable
to:
Neenah
Printing
Ann:
Literature
Distribution
Center
P0.
Box
506
Neenah,
WI
54957-0506
LIII
Purchase
Order
________________
Mastercard
Name
of
Card
holder
Account
#__________
Cardholders
signature
To
Order
call
920-751-2120
or
Fax
920-751-2121
Exp.
Date
visa
SELF-PACED
TRAINING
COURSE
FROM
MILLER
ELECTRIC
-
Learn
the
basics
of
welding
equipment
troubleshooting
and
servicing
with
this
three
module
course
designed
for
home
study,
industrial
and
educational
use.
This
course
will
provide
the
basic
knowledge
to
begin
a
career
in
servicing
welding
equipment,
act
as a
refresher,
or
provide
a
welding
salesman
or
technician
service
and
troubleshooting
techniques.
A
certificate
of
completion
is
awarded
by
the
Miller
Training
Department
upon
successful
completion
of
the
course.
MODULE
1
Visual
Inspection
High
Frequency
Safety
MODULE
2
Volt-ohm
Meter
Operation
Load
Bank
Operation
MODULE
3
Electronic
Symbols
Component
Identification
Troubleshooting
Distributor
Name
Customer
#
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Miller KK215443 Owner's manual

Miller
Brand
Miller
Model
KK215443
Category
Welding System
Type
Owner's manual
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