Miller Electric Mfg. Co | Miller Electric OM-129, 500DX R manual

Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number

Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

Resources Available

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

To locate distributor nearest you call 1-800-4-A-Miller.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Contact the Delivering Carrier for:	File a claim for loss or damage during
For assistance in filing or settling claims,	shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.

PRINTED IN USA	♥ 1999 Miller Electric Mfg. Co. 7/99

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Miller Electric OM-129, 500DX R manual Miller Electric Mfg. Co, To locate distributor nearest you call 1-800-4-A-Miller

Contents

Processes OM-129 647WDescription From Miller to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards ARC Rays can burn eyes and skin Engine Hazards Engine Exhaust Gases can kill Battery Explosion can BlindMoving Parts can cause injury Engine Heat can cause fire Radiation can cause interference Principal Safety StandardsEMF Information ARC Welding can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereux DES 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’ouïe LA 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 blesser LE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécuritéInformation sur les champs électromagnétiques Consignes relatives aux stimulateurs cardiaques Weld, Power, And Engine Specifications − SpecificationsSymbols And Definitions − Definitions Fuel Consumption Dimensions, Weights, And Operating AnglesCurve shows typical fuel use under weld or power loads 1898 lb 861 kg Engine End Duty Cycle And Overheating AC Auxiliary PowerWarranty Minutes Welding Minutes Resting 60% Duty Cycle At 500 Amperes Duty Cycle is Percentage Volt-Ampere Curves CC/DC Standard CV/DC Models With CV Option Optional AC Power Plant Curves Do Not Lift Unit From End Airflow Clearance − InstallationInstalling Welding Generator Location Charger Activating The Dry Charge BatteryWhen electrolyte is low, add Maintain proper level Connect Negative − Cable Last Connecting The BatteryEngine Prestart Checks Tools Needed 1/2 Connecting To Weld Output Terminals Selecting Weld Cable Sizes After installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote A/V Control Receptacle RC3 Socket Remote 14 Receptacle RC3 Information OptionalTerminal Strip 2T Connections Optional Stop engine − Operating the Welding Generator Standard Controls See Section If 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 belt Controls 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 RC1 Australian And South African Receptacle Options Optional Auxiliary Power ReceptaclesGfci Receptacle Option British Receptacle Option 1011 Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power Load Terminals − Maintenance & Troubleshooting Maintenance Label Deutz F3L912 Diesel Engine To clean air filter Servicing Air CleanerHose Servicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine Speed1850 13 mm Max Tools Needed 11/16 To adjust belt tensionChecking And Replacing Alternator Belt Stop engine To check belt tension Resetting 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 cool Troubleshooting Welding Auxiliary Power Engine Trouble Remedy OM-129 647 − Electrical Diagrams Circuit Diagram For Welding Generator Standard Models Circuit Diagram For Welding Generator Models With CV Option 184 954-C − RUN-IN Procedure Wetstacking Run-In Procedure Using Load Bank Load Bank Bank/grid Run-In Procedure Using Resistance GridDo not touch hot exhaust From flammables Selecting Equipment − Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Industrial 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting Amperage Volts Welding Generator Auxiliary Power output circuit Generator is to supply standby power duringEmergencies or power outages Customer-supplied equipment is required if Selecting Extension Cord Use Shortest Cord Possible − Parts List 101 100 66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item Generator 6 5 Generator -1 Item Hardware is common Not available unless listed 171Includes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Your distributor also gives ServiceSupport To locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. CoFor assistance in filing or settling claims