Miller Electric DS-75D12, DS-75S16, DS-75S12, and DS-75D16 manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

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 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 the 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 specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-230 300AProcesses File MIG GmawFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killCalifornia Proposition 65 Warnings About Pacemakers Principal Safety StandardsEMF Information Indique un message de sécurité particulier UNE Décharge Électrique peut entraîner la mortLES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer unIncendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures graves’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesDo not remove Safety Collar until instructed to SpecificationsInstalling Swivel Into Pipe Post RatingInstalling Control Box And Adjusting Tilt Installing Boom And Reel SupportInstalling Wire Guide Extension Installing GuardEquipment Connection Diagram Pin Information Control Box ConnectionsPin Plug Information Motor Speed Wire Type Wire Size Feed Speed Capability Removing Safety Collar And Adjusting BoomWire Type, Size, And Feed Speed Capability Table Gun Recommendation TableInstallation Installing Drive RollsDrive Roll Carrier Ejector Button Pressure Door Assembly RemovalInstalling PD Continuous Wire Guides Installing PD continuous wire guides with PD drive rollsInstalling Non-PD Old Style Wire Guides Installing wire guides with non- PD old- style drive rollsInstalling gun with Accu-Mate connec- tion Installing Welding GunInstalling gun without Installing gun without Accu-Mate con- nectionInstall gun. Lay gun cable out straight. Cut off Above To adjust drive roll pressure, hold nozzleSettings When installing gun, the liner should extend Cut wire offManually Adjusted Run-In S1-1 And S1-2 Setting Internal DIP Switches On Motor BoardsRun-In Disabled S1-1 Left Side Motor Control Board PC101 Right Side MotorEquipment DIP Switch Settings For Models With Meters Only Digital Meter DIP Switch SettingJog/Purge Power SwitchLeft/Right Select Switch Voltage Control And Digital Meters Trigger Hold SwitchTrigger Hold Switches Voltage ControlsDisconnect power before maintaining Routine MaintenanceBrush Inspection And Replacement = Check ~ = Clean = Replace Reference EveryDiagnostics Trouble Remedy TroubleshootingDisconnect power before troubleshooting OM-230 300 − Electrical Diagram 204 716-B − Parts List Quantity Control Box Harness Connectors/Receptacles 193 Knob, Pointer 1.250 Dia x .250 Id W/Two Set ScrewsBoom Assembly Boom Assembly -1 Item Drive Roll & Wire Guide Kits See -1 ForDrive Assembly With Motor Left Side Shown Support, Hub & Reel PD-V Page Page Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s