Miller Electric OM-220 390F Owner's Manual

ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW) WeldingEngine Driven Welding Gene

OM-144 152 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des ét

OM-144 152 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouv

OM-144 152 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des

OM-144 152 Page 9SECTION 2 – DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Start Engine EngineCheck engine belt Oil Pressure

OM-144 152 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 58 (1473 mm)ACWidth 32 (813 mm)ABCDepth 68 in (1727 mm)D Do not exc

OM-144 152 Page 113-4. Duty Cycle And Overheatingsb1.1 8/93 SB-134 397-ADuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithou

OM-144 152 Page 123-6. Volt-Ampere Curves SB-133 004 / SB-133 003The volt-ampere curve shows theminimum and maximum voltageand amperage output capabil

OM-144 152 Page 13SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

OM-144 152 Page 144-3. Activating The Dry Charge Batterydrybatt1 2/96 – S-0886Remove battery from unit.1 Eye Protection – SafetyGlasses Or Face Shield

OM-144 152 Page 154-4. Connecting The Battery–+ Connect Negative (–)Cable Last.ST-153 654-B / Ref. SD-131 784-A / Ref. S-0756-BOFFSTARTRUN4-5. Engine

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

OM-144 152 Page 164-6. Connecting To Weld Output Terminals1 Positive (+) Weld OutputTerminals2 Negative (–) Weld OutputTerminalsFor Direct Current Ele

OM-144 152 Page 174-7. Weld Output Terminals And Selecting Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding*

OM-144 152 Page 184-8. Remote 14 Receptacle RC3 InformationSocket* Socket InformationAJBKIA 24 volts ac. Protected by circuitbreaker CB4.BCLNHDMGEFB C

OM-144 152 Page 194-9. Terminal Strip 3T ConnectionsRef. ST-131 784-A / Ref. ST-121 578-D / Ref. S-184 781 Stop engine.If remote control plug does no

OM-144 152 Page 20SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Front Panel ControlsST-134 687-B12 4 5678910111215 14 1331 Voltmeter2 Ammeter3 Amper

OM-144 152 Page 215-2. Example Of Remote Amperage ControlSet SwitchesAdjust Remote ControlSet PercentageMin = 55 A DC/CCPercentage Of Range = 50%Max =

OM-144 152 Page 22SECTION 6 – OPERATING AUXILIARY EQUIPMENT6-1. Generator Power Receptacles And Circuit BreakersRef. ST-174 733 / ST-174 757 If unit

OM-144 152 Page 23SECTION 7 – MAINTENANCE & TROUBLESHOOTING7-1. Routine MaintenanceRecycleenginefluids. Stop engine before maintaining. See also

OM-144 152 Page 247-2. Maintenance Label

OM-144 152 Page 257-3. Servicing Air Cleaneraircleaner2 2/01– ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without airc

The following terms areused interchangeablythroughout this manual:Stick = SMAWMIG = GMAWCALIFORNIAProposition 65WarningDiesel engine exhaust andsome o

OM-144 152 Page 267-4. Servicing Fuel And Lubrication SystemsRef. ST-153 653-A / Ref. SD-131 784 Stop engine and let cool.1 Oil Filter2 Oil Drain Plu

OM-144 152 Page 277-5. Adjusting Engine Speed Stop engine.Engine speeds have been factoryset and should not require adjust-ment. After tuning engine,

OM-144 152 Page 287-7. Checking And Replacing Engine BeltRef. ST-134 730-B / SD-131 784-A Stop engine, and let cool.A V-belt drives the engine coolin

OM-144 152 Page 297-9. Adjusting Overspeed Shutdown ValveDrawing # Stop engine, and let cool.The overspeed shutdown valveprotects the engine from dam

OM-144 152 Page 307-10. TroubleshootingA. WeldingTrouble RemedyNo weld output. Be sure Ampere Range switch is not set between positions.Disconnect equ

OM-144 152 Page 31C. EngineTrouble RemedyEngine does not start. Check fuel level (see Section 4-5).Check battery, and replace if necessary.Check oil l

OM-144 152 Page 32SECTION 8 – ELECTRICAL DIAGRAMFigure 8-1. Circuit Diagram For Welding Generator

OM-144 152 Page 33SD-169 551-B

OM-144 152 Page 34SECTION 9 – RUN-IN PROCEDURErun_in1 8/019-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do not

OM-144 152 Page 359-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhau

OM-144 152 Page 369-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep

OM-144 152 Page 37SECTION 10 – GENERATOR POWER GUIDELINES10-1. Selecting Equipmentgen_pwr 6/02 – Ref. ST-159 730 / ST-800 5771 Generator Power Recepta

OM-144 152 Page 3810-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-144 152 Page 3910-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-144 152 Page 4010-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-144 152 Page 4110-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step

OM-144 152 Page 4210-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable

OM-144 152 Page 4310-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles

OM-144 152 Page 44SECTION 11 – PARTS LIST12345689 10 11121314151617181921229365667165667273 7277578808273838486858788899092Fig 11-2Fig 11-4Fig 11-3720

OM-144 152 Page 452324252627 28303130323335 36383940414243444547 4660546129Fig 11-5ST-134 499-D37484950515253*555657585947486263*Includes Item 5434

OM-144 152 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_7/021-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardsw

OM-144 152 Page 46DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 Fig 11-2 PANEL, front w/components 1. . . . . . . . . . . . .

OM-144 152 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity53 130 435 ENGINE, deutz dsl elec (consisting of) 1.

OM-144 152 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity99 118 790 ANGLE, strain relief 1. . . . . . . . .

OM-144 152 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 1)Quantity1 S3 131 213 SWITCH, range/changeo

OM-144 152 Page 5012345678 910111213 14 15161718192021222324251891ST-134 501-A Hardware is common andnot available unless listed.Figure 11-3. Panel,

OM-144 152 Page 51QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Panel, Front Lower w/Components (Fig 11-1 Item 90)1 038 612 TERMINAL ASSEMBLY

OM-144 152 Page 52DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-4. Control Box (Fig 11-1 Item 2)Quantity1 2T 129 939 BLOCK, term 10A 19P 1. . . . . . .

OM-144 152 Page 53DescriptionPartNo.ItemNo.Figure 11-5. Generator (Fig 11-1 Item 60)Quantity1 173 066 BRACKET, mtg brushholder 1. . . . . . . . . .

OM-144 152 Page 54Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

OM-144 152 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The f

PRINTED IN USA  2002 Miller Electric Mfg. Co. 5/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-144 152 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securel

OM-144 152 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcomm

OM-144 152 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 4/021-1. Signification des symbolesSignifie Mise en garde ! Soy