Miller Electric OM-129, 500DX R manual From Miller to You

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Miller is the first welding equip- ment manufacturer in the U.S.A. to be registered to the ISO 9001 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 which 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 catalog sheets. To locate your nearest distributor call 1-800-4-A-Miller.

Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.

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Contents Description OM-129 647WProcesses From Miller to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards ARC Rays can burn eyes and skinEngine Hazards Engine Exhaust Gases can kill Battery Explosion can BlindMoving Parts can cause injury Engine Heat can cause fireRadiation can cause interference Principal Safety StandardsEMF Information ARC Welding can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécuritéInformation sur les champs électromagnétiques Consignes relatives aux stimulateurs cardiaquesWeld, Power, And Engine Specifications − SpecificationsSymbols And Definitions − DefinitionsFuel Consumption Dimensions, Weights, And Operating AnglesCurve shows typical fuel use under weld or power loads 1898 lb 861 kg Engine EndDuty Cycle And Overheating AC Auxiliary PowerWarranty Minutes Welding Minutes Resting 60% Duty Cycle At 500 Amperes Duty Cycle is PercentageVolt-Ampere Curves CC/DC Standard CV/DC Models With CV OptionOptional AC Power Plant Curves Do Not Lift Unit From End Airflow Clearance − InstallationInstalling Welding Generator LocationCharger Activating The Dry Charge BatteryWhen electrolyte is low, add Maintain proper levelConnect Negative − Cable Last Connecting The BatteryEngine Prestart Checks Tools Needed 1/2Connecting To Weld Output Terminals Selecting Weld Cable SizesRemote A/V Control Receptacle RC3 Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Socket Remote 14 Receptacle RC3 Information OptionalTerminal Strip 2T Connections Optional Stop engine− Operating the Welding Generator Standard Controls See SectionIf light goes off, stop engine and check oil level Do not switch under loadDescription Of Standard Controls See Section If light goes on, stop engine and check engine beltControls For Models With CV Option See Section This unit has a max OCV control circuit Volt And 240 Volt Duplex Receptacles Auxiliary power is not affected by weld output− Operating Auxiliary Equipment 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1Australian And South African Receptacle Options Optional Auxiliary Power ReceptaclesGfci Receptacle Option British Receptacle Option1011 Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power Load Terminals− Maintenance & Troubleshooting Maintenance Label Deutz F3L912 Diesel EngineHose Servicing Air CleanerTo clean air filter Servicing Fuel And Lubrication Systems 1850 Adjusting Engine SpeedServicing Optional Ether Starting Aid 13 mm Max Tools Needed 11/16 To adjust belt tensionChecking And Replacing Alternator Belt Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Overload Protection For Models With CV Option Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Stop engine and let coolTroubleshooting WeldingAuxiliary Power EngineTrouble Remedy OM-129 647 − Electrical Diagrams Circuit Diagram For Welding Generator Standard ModelsCircuit Diagram For Welding Generator Models With CV Option 184 954-C − RUN-IN Procedure WetstackingRun-In Procedure Using Load Bank Load BankBank/grid Run-In Procedure Using Resistance GridDo not touch hot exhaust From flammablesGrounding Generator To Truck Or Trailer Frame − Auxiliary Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting Amperage VoltsWelding Generator Auxiliary Power output circuit Generator is to supply standby power duringEmergencies or power outages Customer-supplied equipment is required ifSelecting Extension Cord Use Shortest Cord Possible − Parts List 101 10066 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item Generator 6 5Generator -1 Item Includes 171Hardware is common Not available unless listed Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Support ServiceYour distributor also gives For assistance in filing or settling claims Miller Electric Mfg. CoTo locate distributor nearest you call 1-800-4-A-Miller