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Manual Miller Electric D-75D

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  • Miller Electric D-75D - page 1

    D-75S, D-75D Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-228 322A 2006 − 06 File: MIG (GMA W) V isit our website at www.MillerWelds.com ...

  • Miller Electric D-75D - page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...

  • Miller Electric D-75D - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric D-75D - page 4

    dec_wire_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phon ...

  • Miller Electric D-75D - page 5

    OM-228 322 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me ...

  • Miller Electric D-75D - page 6

    OM-228 322 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...

  • Miller Electric D-75D - page 7

    OM-228 322 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. ...

  • Miller Electric D-75D - page 8

    OM-228 322 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W ...

  • Miller Electric D-75D - page 9

    OM-228 322 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy m bole graphique d’av ertiss ement ! Attention ! Cette pro- cédur e c omport e d es risques poss ib ...

  • Miller Electric D-75D - page 10

    OM-228 322 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...

  • Miller Electric D-75D - page 11

    OM-228 322 Pa ge 7 2-3 . Dangers s upplé mentaire s e n rela t i on a v ec l’installa tion, l e fonctionneme nt e t la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surchar ...

  • Miller Electric D-75D - page 12

    OM-228 322 Page 8 2-5. Princi pales n ormes de sécu rité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...

  • Miller Electric D-75D - page 13

    OM-228 322 Page 9 SECTION 3 − DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear . 1 Electric s ...

  • Miller Electric D-75D - page 14

    OM-228 322 Page 10 3-2. WEEE Label Do not discard this product with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility . Contact your local recycling office or your local distributor for further information. ST-178 794-A 50/60 S/N: 24 10.0 Hz 50/60 IP 21 V 100 A 750 X ...

  • Miller Electric D-75D - page 15

    OM-228 322 Page 1 1 SECTION 4 − INTRODUCTION 4-1. Specifications T ype of Input Power W elding Power Source T ype W elding Circuit Rating IP Rating Overall Dimensions Maximum Spool W eight Wire Feed Speed Range Wire Diameter Range W eight 24 V olts ac Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin, that Provides V oltag ...

  • Miller Electric D-75D - page 16

    OM-228 322 Page 12 5-2. Equipment Connection Diagrams 1 W elding Power Source 2 Contactor Control/Power Cord 3 Weld Cable 4 Weld Cable 5 W orkpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder and Regulator (Customer Supplied) . Shielding gas pressure not to exceed 100 PSI (689 kPa). 804 564-B 1 2 3 4 5 6 7 8 9 ...

  • Miller Electric D-75D - page 17

    OM-228 322 Page 13 5-3. Rear Panel Connections And Rotating Drive Assembly 804 557-B / 804 184-B 2 1 14-Pin Control Cable - 10 Ft (3.0 m) 2 Shielding Gas V alve Fittings Requires fitting with 5/8-18 right-hand threads. Connect customer-supplied gas hose. 3 Jumper W eld Cable . If welding at 350 amps or less, connect jumper weld cable to connection ...

  • Miller Electric D-75D - page 18

    OM-228 322 Page 14 5-4. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. A J K B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I L G Circuit common for 24 volts ac circuit. C L N H D M G C +10 volts dc input from power source to wire feeder with respect to socket D. D M G E F D Rem ...

  • Miller Electric D-75D - page 19

    OM-228 322 Page 15 5-8. Installing PD Continuous Wire Guides Ref. 804 188-B . PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls. . 70 series wire guides are not compatible with 75 series w ...

  • Miller Electric D-75D - page 20

    OM-228 322 Page 16 5-9. Installing Non-PD (Old Style) Wire Guides Ref. 804 192-C Installing wire guides with non- PD (old-style) drive rolls . Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. 1 Pressure Door Assembly 2 PD Inlet Guide 3 Intermediate Guide 4 Set Screw 5 Guide Holder 6 Exit ...

  • Miller Electric D-75D - page 21

    OM-228 322 Page 17 5-10. Installing Welding Gun 804 189-C 1 Power Clamp Knob 2 Gun Locking T ab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if ...

  • Miller Electric D-75D - page 22

    OM-228 322 Page 18 5-1 1. Installing W elding Wire And Adjusting Pressure Drive Setting Ref. 804 190-B T ools Needed: 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 8 with 8 being the maximum setting. . When using cored welding wire use knurled drive rolls. . For aluminu ...

  • Miller Electric D-75D - page 23

    OM-228 322 Page 19 5-12. Motor Board DIP Switch Settings Position Settings And Results For DIP Switch S1 On PC1 And PC101 Remove wrapper . 1 DIP Switch S1 On Motor Board PC1 and PC101 S1-1 Run-In enable or disable. S1-2 Automatic Run-In versus Manual Adjustment Run-in Install wrapper when finished. 1 803 063 / Ref. 802 944 . In the DI P switch S 1 ...

  • Miller Electric D-75D - page 24

    OM-228 322 Page 20 T ools Needed: 1/4 in 5-13. Display Board DIP Switch Settings 12 3 45 Or Meters/Minute Inches/Minute Digital Meter Functions 12 3 45 803 069 Remove wrapper . 1 DIP Switch S2 On Digital Meter Board PC60 Install wrapper when finished. PC60 1 ...

  • Miller Electric D-75D - page 25

    OM-228 322 Page 21 SECTION 6 − OPERA TION 6-1. Power Switch 1 Power Switch 1 Ref. 804 567-B 1 Left/Right Select Switch Pressing the Left/Right Select switch allows the operator to choose which side of the unit’ s con- trols will operate. 6-2. Left/Right Select Switch 1 Ref. 804 568-B 6-3. Jog/Purge Pressing the Jog/Purge switch allows the op- e ...

  • Miller Electric D-75D - page 26

    OM-228 322 Page 22 6-4. T rigger Hold Switch 1 T rigger Hold Switches T rigger hold allows the operator to weld without holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position. • The operator must hold the trig- ger for a minimum of 2 seconds, bu t not longer than 6 seconds be- fore releas ...

  • Miller Electric D-75D - page 27

    OM-228 322 Page 23 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. n = Check ~ = Clean l = Replace Reference Every 3 Months Section 5-2, 5-3 l Unreadable Labels ~ W eld T erminals nl W eld Cable nl Motor Brush Section 5-2, 5-3 n 14-Pin Cord n Gas Hose and Fittings n Gun Cable Every 6 Months Or Section 5-7 ~ ...

  • Miller Electric D-75D - page 28

    OM-228 322 Page 24 7-3. Diagnostics 803 063-A 1 LED3 On Right Side Motor Control Board PC1 2 LED3 On Left Side Motor Control Board PC101 3 LED3 On Dual Board PC70 2 1 3 Display On Optional Meter LED3 Sequence Indicated Error Left Side Motor Control HELP 1 1 1 Blink Communication Error Left Side Motor Control Board PC101 HELP 12 2 Blinks Trigger Err ...

  • Miller Electric D-75D - page 29

    OM-228 322 Page 25 7-4. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity , and repair or replace cables if necessary (see Section 5-3). Wire feeder is on, display does not light up, motor does not run, ...

  • Miller Electric D-75D - page 30

    OM-228 322 Page 26 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram ...

  • Miller Electric D-75D - page 31

    OM-228 322 Page 27 204 716-B ...

  • Miller Electric D-75D - page 32

    OM-228 322 Page 28 SECTION 9 − P ARTS LIST 804 569-B . Hardware is common and not available unless listed. 22 Fig.9-2 23 1 2 3 Fig. 9-3 18 17 16 21 20 15 10 11 12 11 5 8 9 10 7 6 14 9 13 19 4 Figure 9-1. Main Assembly ...

  • Miller Electric D-75D - page 33

    OM-228 322 Page 29 Description Part No. Item No. Figure 9-1. Main Assembly Quantity 1 159 647 Insulator , Motor Clamp 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric D-75D - page 34

    OM-228 322 Page 30 803 049-C . Hardware is common and not available unless listed. 7 3 4 5 6 8 9 10 11 12 5 13 14 16 4 2 15 19 18 17 26 20 21 22 22 21 23 24 25 1 27 Figure 9-2. Control Box Quantity Description Part No. Dia. Mkgs. Item No. Model D-75S D-75D Figure 9-2. Control Box (Figure 9-1 Item 21) 1 204 722 Wrapper , Feeder 1 1 . . . . . . . . . ...

  • Miller Electric D-75D - page 35

    OM-228 322 Page 31 Quantity Description Part No. Dia. Mkgs. Item No. Model D-75S D-75D Figure 9-2. Control Box (Continued) 18 R1, R101 073 562 Potentiometer , Cp Std Slot 1T 2. W 10K Linear D-74S 2 0 . . . . . . . . . . . . . . . . . . . . . . . 18 R1, 101, 70, 170 224 597 Potentiometer , Cermet Std Flat 3.75T 2 W 10K Linear 0 4 . . . . . . . . . . ...

  • Miller Electric D-75D - page 36

    OM-228 322 Page 32 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 186-B 1 22 21 2 20 3 4 5 6 7 8 9 10 20 2 21 13 11 12 14 15 16 18 19 23 17 Figure 9-3. Drive Assembly , Wire (Left Side Drive Assembly Shown) Item No. Diagram marking Part No. Description Quantity Model Left Right Figure 9 ...

  • Miller Electric D-75D - page 37

    OM-228 322 Page 33 . Hardware is common and not available unless listed. 804 191-B 1 3 4 5 6 7 2 Figure 9-4. Drive Assembly With Motor (Left Side Drive Assembly Shown) Item No. Diagram marking Part No. Description Quantity Model D-75S D-75D Figure 9-4. Drive Assembly With Motor (Figure 9-1 Item 4) 1 219 103 Screw, 010 − 32x .75 Flathd − Soc Stl ...

  • Miller Electric D-75D - page 38

    OM-228 322 Page 34 Wire Size PD-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 for Old Style Drive Rolls (1 each required) Standard Drive Rolls ( 4 required) Fraction Metric PD-V Kit Roll Guide Roll Inlet Intermediate Exit V Groove U Groove VK Groove UC Groove .023 − .0 ...

  • Miller Electric D-75D - page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou 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 expe ...

  • Miller Electric D-75D - page 40

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mf g. Co. An Illinois T ool Wo rks Co mpany 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headqua rters − ...

Manufacturer Miller Electric Category Welder

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric D-75D by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric D-75D.

A complete Miller Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

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