Miller Electric A1D-4RV, A1D-4RW manual Brush Inspection And Replacement, Troubleshooting

5-3. Brush Inspection And Replacement

	1
	3
2
	1/4 in (6 mm)
	Minimum Length
	5/8 in (16 mm)
	New Length
Tools Needed:	Replace
	Damaged Brushes

1Motor

2Brush Cap

Remove brush cap.

3 Brush

Replace brush if it becomes chipped or broken, or if less than 1/4 in. (6.4 mm) of brush material is left. Do not include spring boss as part of the 1/4 in. measurement.

Install brush so that curved surface on end of brush matches curve of motor, and secure with cap.

Repeat procedure for other brush.

ST-137 390-C / S-0816

5-4. Troubleshooting

	Trouble	Remedy
Wire feeds erratically.		Adjust drive roll pressure by turning pressure adjustment knob(s) 1/4 turn clockwise until wire stops slip-
		ping. Check gun contact tip for obstructions.
		Check size of drive roll (see Section 3-1).
		Replace drive roll if worn (see Section 3-1).
		Clean drive roll, and check wire spool hub tension.
		Check and secure motor plug connection (see Section 3-2).
		Align drive rolls (see Section 5-2).
Wire stops feeding while welding.		Align drive rolls (see Section 5-2).
		Replace motor.
Motor runs slowly.		Reduce load.
		Check for correct input voltage.
Motor runs at full speed regardless of		Have Factory Authorized Service Station/Service Distributor check digital wire drive motor Tachometer
wire speed setting.		board and encoder disc.
Operation Module servo light on, Teach		Check and secure servo warning light(s) connection.
Pendant display on, servo warning
light(s) off (A1D-4RV model only).
		Replace burned out servo warning light(s).

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