Miller Electric D-74D Owner'S Manual Download Page 24 | Manualshive

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OM-1500-6 Page 20

SECTION 7

−

MAINTENANCE

7-1. Routine Maintenance

Y

Disconnect power before maintaining.

3 Months

Replace

unreadable

labels.

Clean and

tighten

weld

terminals.

Repair or

replace

cracked

weld

cable.

Check

14-pin cord.

Check gas

hose and

fittings.

Check gun

cable.

Replace

cracked

parts.

6 Months

Blow out or vacuum

inside. During heavy

service, clean

monthly.

Or

Clean

drive rolls.

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Summary of Contents for D-74D

Page 1: ...D 74S D 74D Processes Description MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Wire Feeder OM 1500 6 206 805H 2006 05 File MIG GMAW Visit our website at www MillerWelds com ...

Page 2: ...ntinue 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 operatio...

Page 3: ...s 9 3 2 Rating Label For CE Products 10 3 3 Symbols And Definitions 10 SECTION 4 INTRODUCTION 11 4 1 Specifications 11 SECTION 5 INSTALLATION 11 5 1 Site Selection 11 5 2 Equipment Connection Diagrams 12 5 3 Rear Panel Connections And Rotating Drive Assembly 13 5 4 14 Pin Plug Information 14 5 5 Gun Recommendation Table 14 5 6 Wire Type Size And Feed Speed Capability Table 14 5 7 Installing And Th...

Page 4: ...ctives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 98 37 EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 5 Wire Feeders IEC 60974 5 Ed 1 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Powe...

Page 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shield...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ... Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The ...

Page 9: ...n selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du sectionne...

Page 10: ...le de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules m...

Page 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Page 12: ...Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans les...

Page 13: ...g fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3...

Page 14: ...mbols are found only on CE products Note A Amperes V Volts AlternatingCurrent X Duty Cycle IP Degree Of Protection Hz Hertz Program Wire Feed Jog Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Off Purge Press To Set Start Crater Time Preflow Time Postflow Time Read Instructions Increase I1 Primary Current I2 Rated Current U2 Load Voltage U1 Primary Voltage A B Dual Sch...

Page 15: ...b 27 kg 100 Volts 750 Amperes 100 Duty Cycle IP 21 Length 35 in 889 mm Width 12 1 2 in 318 mm Height 14 in 356 mm 87 lb 39 5 kg SECTION 5 INSTALLATION Ref 803 048 Y Do not put feeder where welding wire hits cylinder Y Do not move or operate equipment when it could tip 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source 3 Wire Spool Ree...

Page 16: ...Power Source 2 Contactor Control Power Cord 3 Positive Weld Cable 4 Negative Weld Cable 5 Workpiece 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 803 068 1 2 3 4 5 6 7 8 9 ...

Page 17: ...quires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 3 Weld Cable Terminal 4 Jumper Weld Cable 5 Weld Cable 6 Drive Assembly 7 Drive Assembly Rotation Knob 8 Rating Label Location To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob 9 16 5 8 in Tools Needed 3 16 in 6 7 1 3 4 5 4 5 8 ...

Page 18: ...ack 0 to 10 volts dc 1 volt per 10 arc volts F Current feedback 0 to 10 volts dc 1 volt per 100 amperes The remaining pins are not used 5 5 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires Roughneck C Series Guns 300 400 500 And 600 Amp FCAW Self Shielding Wires FC 1260 Or FC 1150 5 6 Wire Type Size And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability ...

Page 19: ...mall diameter stainless steel wire reduce drive roll pressure on the rear roll to half that of the front rolls To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If con tact tip is completely blocked wire should slip at the feeder see pressure adjust ment abov...

Page 20: ...n 14 pin receptacle on machines that don t provide current feed back Install wrapper when finished 1 803 063 Ref 802 944 In the DIP switch S1 illustrations the elevated slider on each switch is shown in white For example the switches above are all in the Off position When DIP switch positions are changed the unit must be turned Off and then On again in order for the new settings to be active DIP s...

Page 21: ...Or Or High Speed Motor Meters Minute High Speed Motor Inches Minute Standard Motor Meters Minute Standard Motor Inches Minute Digital Meter Functions 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 803 069 Remove wrapper 1 Digital Meter Board PC60 2 Meter Board Switch S2 Install wrapper when finished PC60 1 2 ...

Page 22: ...for 3 seconds If the welding arc does not initiate in 3 sec onds after the gun trigger is activated the unit will perform a jog operation for a maxi mum of two minutes If the gun trigger is still activated after two minutes the jog opera tion is terminated to prevent complete des pooling of the wire as in the case of a dam aged gun Jog speed can be adjusted with the Wire Speed control when the uni...

Page 23: ...age Control And Digital Meters 3 1 2 1 Voltmeter Displays actual or preset voltage from welding power source through the 14 pin control cable 2 Wire Speed Meter Displays preset and actual wire feed speed while welding Factory set to display inches per minute If display of meters per min ute is desired see Section 5 9 3 Voltage Controls Use controls to adjust voltage out put of welding power source...

Page 24: ...maintaining 3 Months Replace unreadable labels Clean and tighten weld terminals Repair or replace cracked weld cable Check 14 pin cord Check gas hose and fittings Check gun cable Replace cracked parts 6 Months Blow out or vacuum inside During heavy service clean monthly Or Clean drive rolls ...

Page 25: ...ks in this period indicates the type of error The priority of the errors is related to the num ber of blinks indicating the error The more blinks the more severe the error motor error is top priority A higher priority error overrides a lower one if a motor error and a communica tion error existed the light would blink four times for the motor error The communication error occurs 2 5 sec onds after...

Page 26: ...elding Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 5 7 Change to correct size drive roll see 5 7 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozzle opening Have Factory Authorized Service Agency check drive moto...

Page 27: ...OM 1500 6 Page 23 Notes ...

Page 28: ...OM 1500 6 Page 24 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 29: ...OM 1500 6 Page 25 204 716 B ...

Page 30: ... 1500 6 Page 26 SECTION 9 PARTS LIST 803 050 A Hardware is common and not available unless listed 14 6 7 10 9 8 11 5 12 11 10 15 19 20 16 17 18 3 2 1 22 4 Fig 9 3 21 Fig 9 2 9 13 Figure 9 1 Main Assembly ...

Page 31: ...g STL 875 Od X 12Ga Wall X 2 500 2 14 135 205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 15 141 411 Support Spool 1 16 208 339 Extension Dual Clamp L H 1 16 208 338 Extension Dual Clamp R H 1 17 156 243 Clamp Motor Top 2 18 145 639 Strip Buna n 062 X 3 000 X 4 000 Compressed Sht 2 19 139 226 Base 1 20 134 306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 21 Control Box Refer to Figure 9 2 1...

Page 32: ...m 2 2 5 030 170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole 2 2 6 000 527 Blank Snap in Nyl 875 Mtg Hole Black 1 1 7 200 196 Cable Power 11 5ft 8 c 2 14ga 6 18ga consisting of 1 1 8 139 041 Strain Relief 1 1 9 163 519 Cable Port 11 5 Ft 3 5 m 10 079 739 Conn circ cpc clamp str rlf 1 1 11 PLG12 141 162 Housing Plug Pins service kit 1 1 PLG52 174 823 Housing Plug Pins Skts service kit 1 1 PLG74 115 ...

Page 33: ... 2 27 211 989 Fitting w screen 2 2 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Quantity Description Part No Dia Mkgs Harness Connectors Receptacl...

Page 34: ...acer Carrier Drive Roll 4 4 4 149 486 Pin Rotation Arm Rocker 2 2 5 132 750 Arm Pressure 2 2 6 150 520 Spacer Flat Stl 257 Id X 619 Od X 105 2 2 7 133 493 Ring Retaining Ext 250 Shaft X 025thk 2 2 8 133 350 Pin Hinge 1 1 9 M1 101 201 230 Motor Gear 1 8hp 24vdc Standard Speed 1 1 9 M1 101 201 231 Motor Gear 1 8hp 24vdc High Speed 1 1 153 491 Kit Brush Replacement Consisting Of 1 1 153 492 Cap Brush...

Page 35: ...3 115 Weather Stripping Adh 125 X 375 0 1 23 167 387 Spacer Locating 2 2 24 168 825 Drive Pinion 1 2 25 133 308 Ring Retaining Ext 375 Shaft X 025thk 1 1 26 134 834 Hose Sae 187 Id X 410 Od order by ft 2 Ft 0 6 m 27 149 959 Fitting Brs Barbed M 3 16tbg X 312 24 1 1 28 179 265 Adapter Gun Feeder LH 1 1 28 179 264 Adapter Gun Feeder RH 1 1 29 108 940 Screw Cap Stl Hexhd 250 20 X 750 4 4 30 604 538 W...

Page 36: ...32 961 151 074 053 709 7 64 in 110 in 2 8 mm 151 042 053 705 132 962 151 075 053 711 151 059 1 8 in 125 in 3 2 mm 151 043 053 707 151 060 132 963 151 076 053 712 Fraction Metric Wire Size V GROOVE 4 Roll U GROOVE VK GROOVE UC GROOVE Drive Roll 4 Roll Drive Roll 4 Roll Drive Roll 4 Roll Drive Roll Each Kit Contains An Inlet Guide Intermediate Guide And 045 233 Antiwear Guide w 604 612 Setscrew 8 32...

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Page 39: ...n Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushe...

Page 40: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you 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 Contact the Delivering...

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