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Looking for Manual for 1988ish Millermatic 200 so I can fix wire drive motor

1.8K views 3 replies 3 participants last post by  BillE.Dee  
#1 ·
Hello, I am new to this forum and I am the new owner of a Millermatic 200 circa 1988 serial #JJ399109. I am trying to find a copy of the manual for my welder.

It has the 4 pin connector for the spool gun and the two-wire wire feed drive motor. Online I have found a March 1987 manual for welders starting with #JF926444 Form OM-1303 L, and a January 1989 manual for JJ405392 Form OM-1303K. The first manual shows the older 4-wire wire drive motor and a 4-pin spoolmatic connector. The second manual shows a newer 2-wire drive motor and a 14-pin spoolmatic connector. My welder is halfway between these with a newer 2-wire drive motor and the older 4-pin spoolmatic connector. The schematic inside the machine shows SR1&2 rectifiers and is labeled B-114266. The older manual has a similar 2-rectifier schematic labeled B-093-009A for the welding power source. The newer manual has a schematic labeled B-119 327A which only has SR1.

The machine powers up with the clunking of the contactor and clicking of the gas solenoid valve, but the wire feed drive motor does not turn. I have jumpered the connector for the Mig gun so it's not that. I have the SKP-35 Spot Stitch motor control panel and I want to bypass that to see if the drive motor will work then.
I want to get all the documentation I can before I start asking questions about troubleshooting my welder.

Sorry if this doesn't post in the right place. I am new at this.
 
#2 ·
Go to the Miller website, Service section [Here], plug in your Serial Number in the left box, and it will show the link to your correct manual down below.

You might also operate all the controls, such as those for the Spot/Stitch panel, a few or more times to be sure they're making good contact inside.

Just curious; what is your welding background and what other machines do you have or have you used? Any interesting projects or other facts to introduce yourself with? :waving:
 
#3 ·
So I suppose if the Miller website just lists the March 1987 and the January 1989 Manuals I have to make due with that. My welder serial number is much closer to the later manual, and has the 2 wire drive motor and motor speed control board like the later manual. I guess I will have to cut and paste and make my own Manual.

I have played with the Spot/Stitch/Continous controls and can hear the timers working. I was just trying to simplify the setup to see the cause of the wire feed motor not working. I pulled off the two wires feeding the motor and there is no voltage going to the motor when I simulate the trigger pull. The wire feed motor spun when I hot wired it off a 18v lithuim Ion drill battery, So I am thinking it somewhere in the relay / bridges or control boards.

Oh, I make metal sculptures off and on for the last 20 years. I have a couple of plasma cutters, oxy acetylene torches and I use to teach classes.