Miller Wire Feeder D-54A

WARNING! ELECTRIC SHOCK can kill. Do not touch live electrical parts.

Unit and welding power source shut down and disconnected?

Lockout/tagging procedures followed?

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

The unit is protected from damage due to an internal short or excessive overload by fuse F1. Should F1 open, the unit would be completely inoperative.

Sign off on the fuse maintenance

WARNING! HIGH ROTATIONAL SPEED may cause damage to drive rolls and injure personnel.

Do not allow drive rolls to rotate at high speed if compressed air is used for cleaning the drive roll assembly.

WARNING! ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down unit and welding power source and disconnect input power employing 'lockout/tagging procedures' before inspecting, maintaining, or servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Drive rolls removed and cleaned

IMPORTANT Failure to properly maintain the drive rolls can result in a buildup of wire particles which decreases the efficiency of the wire feeding operation.

Sign off on the drive rolls cleaning

IMPORTANT: Periodically inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary.

WARNING! ELECTRIC SHOCK can kill. WELDING WIRE can cause puncture wounds. HOT SURFACES can burn skin.

Shut down unit and welding power source and disconnect input power employing 'lockout/tagging procedures' before inspecting, maintaining, or servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Allow gun and unit to cool before touching.

Do not depress gun trigger while performing maintenance on gun.

Inspect gun for broken areas, cracks, and loose parts: tighten, repair, and replace as required.

Carefully remove any weld spatter or foreign matter which may accumulate around the nozzle orifice. Use a hardwood stick, never a metal tool.

Repair or replace, as required, all hose and cable; give particular attention to frayed and cracked insulation and areas where it enters equipment.

WARNING! ELECTRIC SHOCK can kill. Do not touch live electrical parts.

Shut down unit and welding power source and disconnect input power employing 'lockout/tagging procedures' before inspecting, maintaining, or servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

If either drive gear does not turn freely, clean the drive shafts and clutch assemblies in the large spur drive gear and repack with a good quality gear grease.

Use the procedure outlined below to remove the drive shafts. Where operating conditions are severe, more frequent inspections should be made.

Retract wire past drive housings.

Remove drive gears in both drive roll housings.

WARNING! ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down unit and welding power source and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Work on internal parts to be performed only by qualified persons.

CAUTION! DISASSEMBLY OF MOTOR FIELD MAGNETS can result in personal injury and equipment damage. Limit drive motor repairs to brush replacement.

The field magnets are very strong. If disassembly is attempted, injury to fingers and hands may result from the rotor being drawn back into the motor. The field magnets are matched sets and operation may be affected if the magnets are tampered with. Warranty is void if the motor is tampered with.

Open brush cap by sliding screwdriver under catch and lifting. Remove brush cap.

Grasp spring retaining bracket with long-nose pliers.

Push spring retaining bracket in slightly and move towards brush. This should release the spring assembly and it can be removed.

Pull brush out using brush pigtail.