Miller Electric and DS-75D16 Owner's Manual

DS-75S12, DS-75S16, DS-75D12, and DS-75D16OM-230 300A2006−09ProcessesDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) Welding(Gas-and Self-Shielding)Sub

OM-230 300 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-230 300 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D

OM-230 300 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

OM-230 300 Page 9SECTION 3 − INTRODUCTION3-1. SpecificationsType of InputPowerWelding PowerSource TypeWire Feed SpeedRangeWire DiameterRangeWelding Ci

OM-230 300 Page 104-2. Installing Control Box And Adjusting Tilt1 Weld Control2 Bracket3 ScrewBracket and screws are installedonto bottom of control a

OM-230 300 Page 114-4. Installing Wire Guide ExtensionST-152 3831 Wire Guide Fitting2 Bolt3 Monocoil Liner4 Wire Guide ExtensionTighten bolt to secure

OM-230 300 Page 12804 784-AY Turn Off wire feeder andwelding power source. Stopengine on weldinggenerator.Y Use only with CC/CV DCPower Sources.1 Cons

OM-230 300 Page 13Ref. 803 1871 Interconnecting Cables2 Interconnecting CableReceptacles3 14-Pin Cord4-7. Control Box Connections1324-8. 14-Pin Plug I

OM-230 300 Page 144-9. Removing Safety Collar And Adjusting BoomST-142 599-C1 Locking KnobTighten knob to prevent boommovement. Loosen knob to allowbo

OM-230 300 Page 1512434-12. Installing Drive Rolls804 737-A1 Drive Roll Carrier2 Ejector Button3 Drive Roll4 Pressure Door AssemblyInstallationOpen pr

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-230 300 Page 164-13. Installing PD Continuous Wire GuidesRef. 804 731-A. PD Continuous Wire Guides:Should be used with .068/.072 in(1.8 mm) and sma

OM-230 300 Page 174-14. Installing Non-PD (Old Style) Wire GuidesRef. 804 732-AInstalling wire guides with non- PD (old-style) drive rolls. Non-PD (ol

OM-230 300 Page 184-15. Installing Welding Gun804 730-A1 Gun Locking Tab2 Power Clamp Knob3 Power Pin Groove4 Gun Connection EndInstalling gun with Ac

OM-230 300 Page 194-16. Installing Welding Wire And Adjusting Pressure Drive SettingNONCONDUCTIVESURFACENONCONDUCTIVESURFACENo Wire Slip Wire SlipsToo

OM-230 300 Page 204-17. Setting Internal DIP Switches On Motor BoardsRemove wrapper.1 DIP Switch S1 On MotorBoards PC1 and PC101.S1-1Run-In enable or

OM-230 300 Page 21Tools Needed:1/4 in4-18. Equipment DIP Switch Settings (For Models With Meters Only)Ref. 803 154 / 803 188Remove wrapper.1 DIP Switc

OM-230 300 Page 22SECTION 5 − OPERATION5-1. Power Switch1 Power Switch1Ref. 803 1831 Left/Right Select SwitchPressing the Left/Right Selectswitch allo

OM-230 300 Page 235-4. Trigger Hold Switch1 Trigger Hold SwitchesTrigger hold allows the operator toweld without holding the gun trigger.• To use the

OM-230 300 Page 24SECTION 6 − MAINTENANCE6-1. Routine MaintenanceY Disconnect power before maintaining.n = Check ~ = Clean l = Replace ReferenceEvery3

OM-230 300 Page 256-3. Diagnostics803 063-A1 LED3 On Right Side MotorControl Board PC12 LED3 On Left Side MotorControl Board PC1013 LED4 On Dual Board

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-230 300 Page 266-4. TroubleshootingY Disconnect power before troubleshootingTrouble RemedyWire feeds, shielding gas flows, butelectrode wire is not

OM-230 300 Page 27Notes

OM-230 300 Page 28SECTION 7 − ELECTRICAL DIAGRAMFigure 7-1. Circuit Diagram

OM-230 300 Page 29204 716-B

OM-230 300 Page 30SECTION 8 − PARTS LIST804 785-A1234561012131416171819202126222Fig 8-4,5Fig 8-2Fig 8-3Fig 8-67891123242528Fig 8-4.5. Hardware is comm

OM-230 300 Page 31QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Model12 16Figure 8-1. Main Assembly1 See Note Control Box, (Fig 8-2) 1 1. . . . . . . . .

OM-230 300 Page 32803 190. Hardware is common andnot available unless listed.345651213154214181716192021212022232418910117Figure 8-2. Control BoxQuant

OM-230 300 Page 33QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.ModelD-75S D-75DFigure 8-2. Control Box (Continued)17 R1,101 073 562 Pot,Cp Std Slot 1t 2.

OM-230 300 Page 34804 786-A12356789101213141516171820212223293015142425261927284. Hardware is common andnot available unless listed.11Figure 8-3. Boom

OM-230 300 Page 35QuantityDescriptionPartNo.ItemNo.Model12 16Figure 8-3. Boom Assembly (Fig 8-1 Item 13)1 010 313 Pin, Cotter Hair .072 X 1.437 4 4. .

OM-230 300 Page 36See Table 8-1 ForDrive Roll & Wire Guide Kits. Hardware is common andnot available unless listed.804 733-A1021298765432022122151

OM-230 300 Page 37. Hardware is common andnot available unless listed.804 734-A2341567Figure 8-5. Drive Assembly With Motor (Left Side Shown)ItemNo.Di

OM-230 300 Page 388769123456713121110ST-081 760-C. Hardware is common andnot available unless listed.Figure 8-6. Support, Hub & ReelDescriptionPar

OM-230 300 Page 39Wire SizePD-V for Hard Wire(1 kit or 4 rolls & 1 guide required)PD-U for Aluminum(1 kit or 4 rolls & 1 guide required)Guides

Notes

Notes

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2006−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2006 Miller Electric Mfg. Co.2006−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-230 300 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these

OM-230 300 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-230 300 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-230 300 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-230 300 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le ris