Miller Electric 500DX R, OM-129 manual Your distributor also gives, Service, Support

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Warranty Questions?

Effective January 1, 1999 (Equipment with a serial number preface of

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Call

1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives

you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1.5 Years Parts − 3 Years Labor

*Original main power rectifiers

*Inverters (input and output rectifiers only)

2.3 Years — Parts and Labor

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Supplies

*Intellitig

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor

*Motor Driven Guns (w/exception of Spoolmate 185)

*Process Controllers

*Positioners and Controllers

*Automatic Motion Devices

*Robots

*RFCS Foot Controls

*IHPS Power Sources

*Water Coolant Systems

*HF Units

*Grids

*Maxstar 140

*Spot Welders

*Load Banks

*SDX Transformers

*Miller Cyclomatic Equipment

*Running Gear/Trailers

*Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

*Field Options

(NOTE: Field options are covered under True Bluefor the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches

*APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

*Remote Controls

*Accessory Kits

*Replacement Parts (No labor)

*Spoolmate 185

Miller’s True BlueLimited Warranty shall not apply to:

1.Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

2.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

3.Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 7/99

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Contents OM-129 647W ProcessesDescription From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs électromagnétiques Principales normes de sécuritéLE Soudage À L’ARC risque de provoquer des interférences Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsCurve shows typical fuel use under weld or power loads Dimensions, Weights, And Operating AnglesFuel Consumption 1898 lb 861 kg Engine EndWarranty Minutes Welding Minutes Resting AC Auxiliary PowerDuty Cycle And Overheating 60% Duty Cycle At 500 Amperes Duty Cycle is PercentageCC/DC Standard CV/DC Models With CV Option Volt-Ampere CurvesOptional AC Power Plant Curves Installing Welding Generator − InstallationDo Not Lift Unit From End Airflow Clearance LocationWhen electrolyte is low, add Activating The Dry Charge BatteryCharger Maintain proper levelEngine Prestart Checks Connecting The BatteryConnect Negative − Cable Last Tools Needed 1/2Selecting Weld Cable Sizes Connecting To Weld Output TerminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote A/V Control Receptacle RC3 Terminal Strip 2T Connections Optional Remote 14 Receptacle RC3 Information OptionalSocket Stop engineStandard Controls See Section − Operating the Welding GeneratorDescription Of Standard Controls See Section Do not switch under loadIf light goes off, stop engine and check oil level 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 − Operating Auxiliary Equipment Auxiliary power is not affected by weld outputVolt And 240 Volt Duplex Receptacles 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1Gfci Receptacle Option Optional Auxiliary Power ReceptaclesAustralian And South African Receptacle Options British Receptacle OptionSet Engine Control switch to Run when using auxiliary power Connecting Optional Auxiliary Power Plant1011 Load Terminals− Maintenance & Troubleshooting Deutz F3L912 Diesel Engine Maintenance LabelServicing Air Cleaner To clean air filterHose Servicing Fuel And Lubrication Systems Adjusting Engine Speed Servicing Optional Ether Starting Aid1850 Checking And Replacing Alternator Belt To adjust belt tension13 mm Max Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerOverload Protection For Models With CV Option Stop engine and let coolWelding TroubleshootingEngine Auxiliary PowerTrouble Remedy OM-129 647 Circuit Diagram For Welding Generator Standard Models − Electrical DiagramsCircuit Diagram For Welding Generator Models With CV Option 184 954-C Wetstacking − RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankDo not touch hot exhaust Run-In Procedure Using Resistance GridBank/grid From flammables− Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage VoltsEmergencies or power outages Generator is to supply standby power duringWelding Generator Auxiliary Power output circuit Customer-supplied equipment is required ifSelecting Extension Cord Use Shortest Cord Possible 101 100 − Parts List66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item 6 5 GeneratorGenerator -1 Item 171 Hardware is common Not available unless listedIncludes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Service Your distributor also givesSupport Miller Electric Mfg. Co To locate distributor nearest you call 1-800-4-A-MillerFor assistance in filing or settling claims