Miller Electric OM-4409 User Manual

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

OM-4409 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les

OM-4409 Page 96DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-5. Air Compressor Assembly (Continued)Quantity53 206698 Plate, Mtg Compressor To Bracket 1

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-4409 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refr

OM-4409 Page 8LES CHAMPS MAGNETIQUES peuv-ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à d

OM-4409 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde

OM-4409 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.

OM-4409 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen

OM-4409 Page 12SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineCheck engine belt Check Air

OM-4409 Page 13SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRatedWeldingOutputMaximumOpen-CircuitVol

OM-4409 Page 144-4. Dimensions, Weights, And Operating AnglesDimensionsHeight54-1/2 in (1384 mm)(to top of muffler)GWidth28-1/2 in (724 mm)(mtg. brack

OM-4409 Page 154-5. Stick And MIG Volt-Ampere Curves208 135 / 203 415 / 208 956The volt-ampere curve shows theminimum and maximum voltageand amperage

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

OM-4409 Page 164-6. TIG Volt-Ampere Curves208 136 / 208 957The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

OM-4409 Page 174-7. Fuel ConsumptionThe curve shows typical fuel useunder weld or generator powerloads.208 2110.000.250.500.751.001.251.501.752.002.25

OM-4409 Page 184-9. Generator AC Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4409 Page 194-10. Optional 3-Phase Generator Power Curves197 472 / 197 473The ac power curves show the gen-erator power available in amperesat the

OM-4409 Page 204-11. Air Compressor Output Curve208 955The air output curve shows the vol-ume and pressure of air availablefrom the air compressor.020

OM-4409 Page 214-13. Manufacturing Rating Label

OM-4409 Page 22SECTION 5 − INSTALLATIONinstall3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712! Always securely fasten weld-ing generator on

OM-4409 Page 235-2. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on base

OM-4409 Page 245-3. Installing Optional Spark Arrestor MufflerTools Needed:803 230! Stop engine and let cool.1 Spark Arrestor Muffler2 Double-Flanged

OM-4409 Page 255-4. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on

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

OM-4409 Page 265-6. Using The Optional Battery Disconnect Switch803 228 / Ref. 803 324! Stop engine.1 Battery Disconnect SwitchThe battery disconnect

OM-4409 Page 275-7. Engine/Compressor Prestart Checks Check all engine/compressor fluidsdaily.Engine must be cold and on a level surface.Unit is ship

OM-4409 Page 285-8. Connecting To Weld Output Terminals803 231 / 803 778-ATools Needed:3/4 inMIG And FCAW WeldingFor MIG welding Direct Current Electr

OM-4409 Page 295-9. Selecting Weld Cable Sizes*Weld OutputTerminalsWeld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***Te

OM-4409 Page 305-10. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-plementary protector

OM-4409 Page 315-11. Connecting To The Air Compressor! Air pressure is present at air shutoffvalve whenever Air Pressure Gaugeon front panel indicates

OM-4409 Page 32SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Controls (See Section 6-2)803 229 / 217 356-A13172111 15 1612 6574831491810

OM-4409 Page 336-2. Description Of Controls (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to energize starting aid for cold

OM-4409 Page 346-3. Process/Contactor Switch217 356-A11 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswitch is

OM-4409 Page 356-4. Using Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Section 5-10).0774 / R

TABLE OF CONTENTSSECTION 7 − OPERATING AUXILIARY EQUIPMENT 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4409 Page 36SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Receptacles21191 624341 120 V 20 A AC GFCI Receptacle GFCI12 240 V

OM-4409 Page 377-2. Connecting To Optional AC Power PlantRef. 197 399 / 802 332-B Do not weld while using optional acpower plant. Place Process/Cont

OM-4409 Page 387-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13 240 V 15 A AC Au

OM-4409 Page 39SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER8-1. Battery Charge Controls1 Output Selector SwitchNOTICE − Do not switch under load. St

OM-4409 Page 408-3. Battery Charge Cable Connections! Stop engine.! Do not charge or jump start a batterywhich has loose terminals or oneshowing damag

OM-4409 Page 418-4. Battery Charging ProcedureStop Engine.Connect Cables (ObserveCorrect Polarity).Set Output Selector Switch ToVoltage Of Battery Bei

OM-4409 Page 428-5. Jump Starting ProcedureConnect Cables (ObserveCorrect Polarity).Set Output Selector Switch ToVoltage Of Battery BeingCharged (12 O

OM-4409 Page 43SECTION 9 − ENGINE/GENERATOR MAINTENANCE9-1. Engine Maintenance Label

OM-4409 Page 449-2. Routine Engine/Generator Maintenance See Section 10 for air compressor maintenance information.! Stop engine before maintaining.

OM-4409 Page 459-3. Checking Generator BrushesRef. 206 467! Stop engine and let cool.1 Generator BrushRemove brushes from brush holder.Replace brushes

OM-4409 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions

OM-4409 Page 469-4. Servicing Engine Air Cleaneraircleaner1 9/00 − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B! Stop engine.NOTICE − Do not run engi

OM-4409 Page 479-5. Inspecting/Cleaning Optional Spark Arrestor Muffler803 228 / 803 230! Stop engine and let cool.1 Spark Arrestor Muffler2 Cleanout

OM-4409 Page 489-6. Adjusting Engine Speed803 228 / 802 313-A! Stop engine and let cool.Engine speed is factory set andshould not require adjustment.

OM-4409 Page 499-7. Servicing Engine Fuel And Lubrication Systems 803 228! Stop engine and let cool.! After servicing, start engine andcheck for fuel

OM-4409 Page 509-8. Engine/Generator Overload Protection! Stop engine. When a supplementary protector,circuit breaker or fuse opens, itusually indica

OM-4409 Page 51SECTION 10 − AIR COMPRESSOR MAINTENANCE Use only genuine Ingersoll Rand compressor oil and filters to maintain 3-year warranty on air

OM-4409 Page 5210-2. Routine Air Compressor Maintenance See Section 9 for engine/generator maintenance information.! Stop engine before maintaining.

OM-4409 Page 5310-3. Servicing Compressor Air Cleaneraircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B! Stop engine.NOTICE − Do not r

OM-4409 Page 5410-4. Compressor Overload Protection! Stop engine. When a circuit breaker or fuseopens, it usually indicates a moreserious problem exi

OM-4409 Page 5510-5. Servicing Air Compressor803 228! Stop engine and let cool. Wait 20 sec-onds for system pressure to drop be-fore changing oil.1 A

OM-4409 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4409 Page 5610-6. Adjusting Compressor Air Pressure803 228Tools Needed:Check compressor air pressure usingair pressure gauge known to be accu-rate.

OM-4409 Page 57SECTION 11 − TROUBLESHOOTING11-1. Troubleshooting TablesA. WeldingTrouble RemedyNo weld output; generator power outputokay at ac recept

OM-4409 Page 58Trouble RemedyConstant speed wire feeder does notwork.Reset supplementary protector(s) CB5 and CB13 (see Section 9-8).Check and secure

OM-4409 Page 59D. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4409 Page 60Trouble RemedyEngine does not run at idle speed. Turn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG.Ch

OM-4409 Page 61SECTION 12 − AIR COMPRESSOR DIAGRAM209 059-AFigure 12-1. Circuit Diagram For Air Compressor

OM-4409 Page 62SECTION 13 − CIRCUIT DIAGRAMFigure 13-1. Circuit Diagram For Welding Generator

OM-4409 Page 63221 915−C

OM-4409 Page 64SECTION 14 − RUN-IN PROCEDURErun_in1 2007−0414-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri

OM-4409 Page 6514-2. Run-In Procedure Using Load BankS-0683! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep exhaust

OM-4409 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt

OM-4409 Page 6614-3. Run-In Procedure Using Resistance GridS-0684! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep e

OM-4409 Page 67SECTION 15 − AIR COMPRESSOR TABLES15-1. Flow Of Free Air (CFM) Through Orifices Of Various DiametersGauge Pressure (psi)Orifice Diamete

OM-4409 Page 6815-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At70-90 P.S.I.G.Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Bu

OM-4409 Page 69SECTION 16 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4409 Page 7016-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4409 Page 7116-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4409 Page 7216-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4409 Page 7316-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4409 Page 7416-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4409 Page 7516-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4409 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4409 Page 76SECTION 17 − SELECTING AND PREPARING A TUNGSTENFOR DC OR AC WELDINGgtaw_Phase_2007−04! Whenever possible and practical, use DC weld ou

OM-4409 Page 77SECTION 18 − GUIDELINES FOR TIG WELDING (GTAW)gtaw 7/200618-1. Positioning The TorchRef. ST-161 892! Grinding the tungsten elec-trode p

OM-4409 Page 7818-2. Torch Movement During WeldingST-162 002-BTungsten Without Filler RodTungsten With Filler RodForm pool Tilt torch Move torch to fr

OM-4409 Page 7918-3. Positioning Torch Tungsten For Various Weld JointsST-162 003 / S-079270°70°90°20°20°10°20°70°40°30°20°70°90°20°Butt Weld And Stri

OM-4409 Page 80SECTION 19 − PARTS LIST Hardware is common and notavailable unless listed. 1234 56789 1011 121314 1516171819 202122 232425 26 27123 12

OM-4409 Page 81803 3243637 38 394041 42 434445464748 495051 52 5354 555657 58 596061626364 656667 68 697071 72 73 747576 7778 798081 8283 847485 86878

OM-4409 Page 82DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-1. Main AssemblyQuantity1 189824 Panel, Gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4409 Page 83DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-1. Main Assembly (Continued)Quantity48 224265 Label, Warning Hot Exhaust Parts Do Not Touch

OM-4409 Page 84DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-1. Main Assembly (Continued)Quantity199505 Hose Assy, Oil Drain 32.000 Lg (includes) 1. . .

OM-4409 Page 85DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-1. Main AssemblyQuantity129 R3 189699 Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt 1. . . . .

OM-4409 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni

OM-4409 Page 86803 325-D812345671011121415171819212226252327139201624Figure 19-2. Control Box AssemblyDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-2. C

OM-4409 Page 87DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-2. Control Box Assembly (Continued)Quantity23 217823 Label, Layout Control Box 1. . . . .

OM-4409 Page 88 Hardware is common andnot available unless listed.11301071328265544425352514950454648473239404138373534314333292757565859165892431823

OM-4409 Page 89DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-3. Panel, Front w/Components (Continued)Quantity206809 Harness, Weld Control (includes) 1.

OM-4409 Page 90DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-3. Panel, Front w/Components (Continued)Quantity41 ♦059773 Switch, Handle (Polarity/AC Swi

OM-4409 Page 91803 327333231124353028292627625248792123221012131120191514181617Figure 19-4. GeneratorDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-4. Ge

OM-4409 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-4. Generator (Continued)Quantity23 172555 Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld 6. . . .

OM-4409 Page 93 Hardware is common andnot available unless listed.802 279-A123465789Figure 19-5. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4409 Page 94 Hardware is common andnot available unless listed.803 328−G45978777675714123456789101112139141115161718192022232425262742931323334706

OM-4409 Page 95DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 19-6. Air Compressor Assembly (Figure 19-1 Item 78)Quantity1 206607 Valve, Ball 1. . . . . .