Troubleshooting, Trouble Remedy | Miller Electric and DS-74DX16

8-2. Troubleshooting

				! Disconnect power before troubleshooting.



	Trouble			Remedy

Wire feeds, shielding gas flows, but elec-				Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see
trode wire is not energized.				Sections 4-5and 4-6).

Wire feeder is on, meter(s) do not light				Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.

Electrode wire feeding stops or feeds er-				Check gun trigger connection. See gun Owner’s Manual.
ratically during welding.

				Check gun trigger. See gun Owner’s Manual.

				Readjust hub tension and drive roll pressure (see Section 4-11).

				Change to correct size drive roll (see Table 10-1).

				Clean or replace dirty or worn drive roll.

				Incorrect size or worn wire guides.

				Replace contact tip or liner. See gun Owner’s Manual.

				Remove weld spatter or foreign matter from around nozzle opening.

				Have Factory Authorized Service Agency check drive motor or motor control board PC1.

Motor runs slowly.				Check for correct input voltage.

Wire does not feed until trigger is pulled,				Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
but continues to feed after trigger is re-
leased, and trigger hold is not on.

Gas valve in feeder is rattling loudly				Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
along with possible erratic or slow wire
feed speed.

Wire feeder power is on, displays light				Check welding gun trigger leads for continuity, and repair leads or replace gun.
up, but unit is inoperative.

OM-1500-14 Page 31

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Miller Electric and DS-74DX16, DS-74DX12 Troubleshooting, Disconnect power before troubleshooting, Trouble Remedy, Pull

Contents

File MIG Gmaw OM-1500-14 207 499HProcesses Description From Miller to You Table of Contents Options and Accessories Warranty HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Flying Metal or Dirt can injure eyes Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosion Moving Parts can cause injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injury About Implanted Medical Devices Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Symboles utilisésUNE Décharge Électrique peut entraîner la mort LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LA Chute DE L’APPAREIL peut blesser LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées Risque D’INCENDIE OU D’EXPLO- Sion LE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-1500-14 − Introduction − InstallationSpecifications Installing Swivel Into Pipe Post Installing Boom And Reel Support Installing Control Box And Adjusting Tilt Installing Wire Guide Extension Exceed 100 PSI 689 kPa Equipment Connection DiagramShielding gas pressure not to Pin Information Control Box ConnectionsPin Plug Information Gun Recommendation Table Removing Safety Collar And Adjusting BoomWire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Ment above. Cut wire off. Close cover Installing And Threading Welding WireAgainst surface. Tighten knob so wire Slip at the feeder see pressure adjust Position Settings And Results For DIP Switch S1 Setting Internal DIP SwitchesWhen DIP switch positions are changed, DIP Switch S1 DIP Switch S4 Not For Customer Use Power Source Selection Menu Operational Terms Power SwitchLeft/Right Select Switch − Operation Time sec Jog/Purge SwitchFront Panel Controls Upper Display To set the correct voltage range for a particular powerProgram Push Button Lower Display Setup Push Button Start Weld Adjust ControlWelding Sequence Diagram Sequence Push Button Auxiliary Menus Trigger Program Select Trigger Hold SetupWire Feed Speed Units Burnback For more information on Sequence Push Button see Section − Setting Sequence ParametersSequence Parameters In a Program Optional Dual Schedule Switch Diagrams − Setting Dual Schedule Parameters There is a two-position DIP DiagnosticsError Error Indications Months − Maintenance & TroubleshootingDiagnostics For User Defined Options Routine Maintenance Pull TroubleshootingDisconnect power before troubleshooting Trouble Remedy Circuit Diagram − Electrical Diagram 204 144-C 10-3 10-2 10-4 29 28 − Parts List Optional Control Box PLG117 165 Harness Connectors/Receptacles Boom Assembly Boom Assembly -1Item Drive Assembly, Wire -1Items 26 Drive Assembly, Wire PLG5 Not available unless listed Hardware is common Kit Roll Drive Roll and Wire Guide KitsFraction Metric RollPage Start Your Professional Welding Career Now Page Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact