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Miller Electric OM-4409 manual

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Table of contents for the manual

  • Page 1

    Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding Engine Driven Welding Generator And Air Compressor OM-4409 206 941V 2007 − 05 TIG (GT A W ) W elding With Optional Equipment: Battery Charging B i g B l u e A i r P a k ® V isit our website at www.MillerWelds.c[...]

  • 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[...]

  • 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 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 7 − OPERA TING AUXILIARY EQUIPMENT 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. 120 V olt And 240 V olt Receptacles 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Connecting T o Optional AC Power P[...]

  • Page 5

    OM-4409 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-4409 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-4409 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

  • Page 8

    OM-4409 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4409 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

  • Page 10

    OM-4409 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4409 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épais [...]

  • Page 12

    OM-4409 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage[...]

  • Page 13

    OM-4409 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’EXT[...]

  • Page 14

    OM-4409 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas [...]

  • Page 15

    OM-4409 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de [...]

  • Page 16

    OM-4409 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Check engine belt Check Air Cleaner Starting Aid Engine Battery (Engine) OPT Jump start/Battery Charge Battery Charge Jump Start Do Not Switch Under Load Read Operator’s Manual Certified/T rained Mechanic Engine Oil [...]

  • Page 17

    OM-4409 Page 13 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open-Circuit V oltage (Nominal) Generator Power Rating Engine Engine Oil Capacity Fuel T ank Capacity CC/DC 20 − 750 A 500 A, 40 V olts DC, 95 Standard CV/DC 14 − 40 V DC, 100% Duty Cycle 600[...]

  • Page 18

    OM-4409 Page 14 4-4. Dimensions, Weights, And Operating Angles Dimensions Height 54-1/2 in (1384 mm) (to top of muf fler) G Width 28-1/2 in (724 mm) (mtg. brackets turned in) 30-3/4 in (781 mm) (mtg. brackets turned out) G ! Do not exceed tilt angles or engine could be damaged or unit could tip. Depth 69-1/2 in (1765 mm) ! Do not move or operate un[...]

  • Page 19

    OM-4409 Page 15 4-5. Stick And MIG V olt-Ampere Curves 208 135 / 203 415 / 208 956 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. C. MIG Mode A. DC Stick Mode B. AC Stick Mode (Optional) 0 20 40 60 80 100 0 100 200[...]

  • Page 20

    OM-4409 Page 16 4-6. TIG V olt-Ampere Curves 208 136 / 208 957 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. DC TIG Mode B. AC TIG Mode (Optional) 0 20 40 60 80 100 0 50 100 150 200 250 300 350 400 450 500 550 [...]

  • Page 21

    OM-4409 Page 17 4-7. Fuel Consumption The curve shows typical fuel use under weld or generator power loads. 208 21 1 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 05 0 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES A T 100% DUTY CYCLE US Gal./Hr . IDLE w/ Air Output Continuous Welding 4-8. Duty Cycle And Overheating [...]

  • Page 22

    OM-4409 Page 18 4-9. Generator AC Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 1 0 2 03 0 4 05 0 6 0 AC AMPERES IN 120V MODE Notes W or k l i k e a P r o! Pros wel d [...]

  • Page 23

    OM-4409 Page 19 4-10. Optional 3-Phase Generator Power Curves 197 472 / 197 473 Th e ac power curves show the gen- erator power available in amperes at the single-phase 120/240 volt re - ceptacle or three-phase 240 volt terminals. A. 12 kV A/kW Single-Phase AC Output (No Weld Load) B. 20 kV A/kW Three-Phase AC Output (No Weld Load) 180 190 200 210 [...]

  • Page 24

    OM-4409 Page 20 4-1 1. Air Compressor Output Curve 208 955 The air output curve shows the vol- ume and pressure of air available from the air compressor . 0 20 40 60 80 100 120 140 0 1 02 03 04 05 06 07 08 09 0 1 0 0 CUBIC FEET PER MINUTE (CFM) POUNDS PER SQUARE INCH (PSI) Idle 4-12. Optional Battery Charging Output Curve 210 269 The battery chargi[...]

  • Page 25

    OM-4409 Page 21 4-13. Manufacturing Rating Label[...]

  • Page 26

    OM-4409 Page 22 SECTION 5 − INST ALLA TION install3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity haza[...]

  • Page 27

    OM-4409 Page 23 5-2. Mounting W elding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. ! Do not mount unit by sup- porting the base only at the four mounting brackets. Use cr[...]

  • Page 28

    OM-4409 Page 24 5-3. Installing Optional Spark Arrestor Muffler T ools Needed: 803 230 ! Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Double-Flanged Elbow 3 Nut 4 Flat W asher 5 Mount 6 Bracket 7 Screw 8 Single-Flanged Elbow 9 Rain Cap 10 Clamp Loosely assemble components as shown.  Mount the muffler with the clean- out plug to the outs[...]

  • Page 29

    OM-4409 Page 25 5-4. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 1 V ent Caps 2 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 3 W ell Fill each cell with electrolyte to bottom of well (maximum). ! Do not overfill batte[...]

  • Page 30

    OM-4409 Page 26 5-6. Using The Optional Battery Disconnect Switch 803 228 / Ref. 803 324 ! Stop engine. 1 Battery Disconnect Switch The battery disconnect switch dis- connects battery voltage from the circuit. When the switch is turned Of f, the front panel controls do not work. T o run unit, turn switch to On posi- tion. T o prevent unit from runn[...]

  • Page 31

    OM-4409 Page 27 5-7. Engine/Compressor Prestart Checks  Check all engine/compressor fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch. H[...]

  • Page 32

    OM-4409 Page 28 5-8. Connecting T o Weld Output T erminals 803 231 / 803 778-A T ools Needed: 3/4 in MIG And FCA W W elding Fo r MIG welding Direct Current Electrode Positive (DCEP), connect wire feeder cable to Positive (+) terminal on left and work cable to Negative ( − ) terminal on right. Use Process/Contactor switch to select type of weld ou[...]

  • Page 33

    OM-4409 Page 29 5-9. Selecting W eld Cable Sizes* W eld Output T erminals W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** T erminals ! T urn off power before connecting to weld output terminals. ! D o not use worn, dam- aged, undersized, or poorly spliced cables. 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m)[...]

  • Page 34

    OM-4409 Page 30 5-10. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG mode. REMOTE OU T[...]

  • Page 35

    OM-4409 Page 31 5-1 1. Connecting T o The Air Compressor ! Ai r pressure is present at air shutoff valve whenever Air Pressure Gauge on front panel indicates air pressure. 1 3/4 in NPT Air Pressure Fitting 2 Air Shutof f V alve Connect air hose with 3/4 in NPT fitting (not supplied) to air shutoff valve. Be sure valve is in open position when us- i[...]

  • Page 36

    OM-4409 Page 32 SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (See Section 6-2) 803 229 / 217 356-A 13 17 2 1 1 1 15 16 12 6 57 4 8 3 14 9 18 10[...]

  • Page 37

    OM-4409 Page 33 6-2. Description Of Controls (See Section 6-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting. Push switch up for 60 seconds to operate the starting aid (intake air heater) before cranking engine (see starting instructions following). 2 Engine Control Switch Use switch t[...]

  • Page 38

    OM-4409 Page 34 6-3. Process/Contactor Switch 217 356-A 1 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in a W eld T erminals Al- ways On position and the en- gine is running. ! DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re- mote On/Off Switch Req[...]

  • Page 39

    OM-4409 Page 35 6-4. Using Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-10 ). 0774 / Ref. 217 356-A / 803 231 Example: Combination Remote Amperage Control (Stick) In Example: Process = Stick (Using Remote On/Off) Range = 125 to 400 A DC Min = 125 A DC Max = 400 A DC Adjust Optio[...]

  • Page 40

    OM-4409 Page 36 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 120 V olt And 240 V olt Receptacles 2 1 191 624 3 4 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops out and receptacle does not wor[...]

  • Page 41

    OM-4409 Page 37 7-2. Connecting T o Optional AC Power Plant Ref. 197 399 / 802 332-B  Do not weld while using optional ac power plant.  Place Process/Contactor switch i n W eld T erminals Always On - Stick position when using optional ac power plant (see Section 6-3). Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connect[...]

  • Page 42

    OM-4409 Page 38 7-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, the GFCI Reset button pops o[...]

  • Page 43

    OM-4409 Page 39 SECTION 8 − OPERA TING OPTIONAL BA TTER Y CHARGER 8-1. Battery Charge Controls 1 Output Selector Switch NOTICE − Do not switch under load. Stop en- gine or set Process/Contactor switch to any Remote position before switching. Use switch to select weld or battery charge output. Output automatically decreases (but does not stop) w[...]

  • Page 44

    OM-4409 Page 40 8-3. Battery Charge Cable Connections ! Stop engine. ! Do not charge or jump start a battery which has loose terminals or one showing damage such as a cracked case or cover . ! Have only qualified persons do bat- tery charging work. ! Keep cables away from moving parts. ! Do not use damaged cables. ! Be sure charger output voltage m[...]

  • Page 45

    OM-4409 Page 41 8-4. Battery Charging Procedure Stop Engine. Connect Cables (Observe Correct Polarity). Set Output Selector Switch T o V oltage Of Battery Being Charged (12 Or 24 V olt). NOTICE − Do not switch under load. + − Start Engine. Set Process/Contactor Switch T o Any Remote On/Off Switch Required Position. In Example: Battery V oltage [...]

  • Page 46

    OM-4409 Page 42 8-5. Jump Starting Procedure Connect Cables (Observe Correct Polarity). Set Output Selector Switch T o V oltage Of Battery Being Charged (12 Or 24 V olt). NOTICE − Do not switch under load. + − Start Engine. Set Process/Contactor Switch T o Any Remote On/Off Switch Required Position.  Charge battery for 10 minutes before jump[...]

  • Page 47

    OM-4409 Page 43 SECTION 9 − ENGINE/GENERA TOR MAINTENANCE 9-1. Engine Maintenance Label[...]

  • Page 48

    OM-4409 Page 44 9-2. Routine Engine/Generator Maintenance  See Section 10 for air compressor maintenance information. ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check ?[...]

  • Page 49

    OM-4409 Page 45 9-3. Checking Generator Brushes Ref. 206 467 ! Stop engine and let cool. 1 Generator Brush Remove brushes from brush holder . Replace brushes if damaged or if brush material is at o r near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Replace Notes 16 Gauge (.063 in) 22 Gauge (.031 in)[...]

  • Page 50

    OM-4409 Page 46 9-4. Servicing Engine Air Cleaner aircleaner1 9/00 − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty . 1 Engine Air Cleaner  The air cleaner primary element can be[...]

  • Page 51

    OM-4409 Page 47 9-5. Inspecting/Cleaning Optional Spark Arrestor Muffler 803 228 / 803 230 ! Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fi[...]

  • Page 52

    OM-4409 Page 48 9-6. Adjusting Engine Speed 803 228 / 802 313-A ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds). If necessary , adjust speed as follows: Start engine and run until warm. T[...]

  • Page 53

    OM-4409 Page 49 9-7. Servicing Engine Fuel And Lubrication Systems 803 228 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Hose And V alve 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/W ater Separator) 5 Petcock 6 S[...]

  • Page 54

    OM-4409 Page 50 9-8. Engine/Generator Overload Protection ! Stop engine.  When a supplementary protector , circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent.  See Section 10-4 for air compres- sor overload protection. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exc[...]

  • Page 55

    OM-4409 Page 51 SECTION 10 − AIR COMPRESSOR MAINTENANCE  Use only genuine Ingersoll Rand compressor oil and filters to maintain 3-year warranty on air compressor . The air compressor warranty w ill be reduced to 2 years if non-Ingersoll Rand oil and filters are used Th e air compressor normally requires service at the intervals listed in the m[...]

  • Page 56

    OM-4409 Page 52 10-2. Routine Air Compressor Maintenance  See Section 9 for engine/generator maintenance information. ! Stop engine before maintaining.  Se e Compressor Maintenance Label for im- portant start-up, service, and storage infor- mation. Service air compressor more often if used in severe conditions. Recycle air compressor fluids. [...]

  • Page 57

    OM-4409 Page 53 10-3. Servicing Compressor Air Cleaner aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run air compressor without air cleaner or with dirty element. Compressor damage caused by using a damaged element is not covered by the warranty . 1 Compressor Air Cleaner  Remove engine air [...]

  • Page 58

    OM-4409 Page 54 10-4. Compressor Overload Protection ! Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Aut h orized Service Agent.  Se e Section 9 -8 for engine/genera- tor overload protection. 1 Circuit Breaker CB15 Circuit breaker CB15 protects the air compressor clutch[...]

  • Page 59

    OM-4409 Page 55 10-5. Servicing Air Compressor 803 228 ! Stop engine and let cool. Wait 20 sec- onds for system pressure to drop be- fore changing oil. 1 Air Compressor Oil Filter 2 Air Compressor Air/Oil Separator 3 Air Compressor Oil Drain Hose w/Removable Cap 4 Air Compressor Oil Fill Cap 5 Air Compressor Oil Level Indicator (On T ank) 6 Oil Sca[...]

  • Page 60

    OM-4409 Page 56 10-6. Adjusting Compressor Air Pressure 803 228 T ools Needed: Check compressor air pressure using air pressure gauge known to be accu- rate. If nece ssary , adjust air pressure as follows: 1 Screw Loosen jam nut securing screw. Turn screw clockwise (increase pressure) or counterclockwise (decrease) until pressure is 125 psi (862 kP[...]

  • Page 61

    OM-4409 Page 57 SECTION 1 1 − TROUBLESHOOTING 1 1-1. T roubleshooting T ables A. Welding T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, or place switch in a Remote On/Of f Switch Required position and connect remote contactor to Remote 14 recep[...]

  • Page 62

    OM-4409 Page 58 T rouble Remedy Constant speed wire feeder does not work. Reset supplementary protector(s) CB5 and CB13 (see Section 9-8). Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10 ). Repair or replace wire feeder . Low CV weld output. Set Ampere Range switch to highest range. Min or max CV weld output only . Check[...]

  • Page 63

    OM-4409 Page 59 D. Engine T rouble Remedy Engine will not crank. Check battery , and replace if necessary . Check battery connections and tighten if necessary . Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9- 8). Have Factory Authorized Service Agent check engine wiring harness and components. Che[...]

  • Page 64

    OM-4409 Page 60 T rouble Remedy Engine does not run at idle speed. T urn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG. Check for obstructed throttle solenoid. Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS 1 and linkage (see Section 9-8). Have Factory Authorize[...]

  • Page 65

    OM-4409 Page 61 SECTION 12 − AIR COMPRESSOR DIAGRAM 209 059-A Figure 12-1. Circuit Diagram For Air Compressor[...]

  • Page 66

    OM-4409 Page 62 SECTION 13 − CIRCUIT DIAGRAM Figure 13-1. Circuit Diagram For Welding Generator[...]

  • Page 67

    OM-4409 Page 63 221 915 − C[...]

  • Page 68

    OM-4409 Page 64 SECTION 14 − RUN-IN PROCEDURE run_in1 2007 − 04 14-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current. NOTIC[...]

  • Page 69

    OM-4409 Page 65 14-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur . 1 Load Bank T urn all l[...]

  • Page 70

    OM-4409 Page 66 14-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur . 1 Resistance Grid[...]

  • Page 71

    OM-4409 Page 67 SECTION 15 − AIR COMPRESSOR T ABLES 15-1. Flow Of Free Air (CFM) Through Orifices Of V arious Diameters Gauge Pressure (psi) Orifice Diameter (in) And Free Air Flow (CFM) 1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4 1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85 2 0.038 0.153 0.342 0.607 1.36 2.43 5.42 9.74 3 0.046 0.188 0.471 0.750 1.68 [...]

  • Page 72

    OM-4409 Page 68 15-2. Approximate Air Consumption (Cubic Feet) T o Operate Pneumatic Equipment At 70-90 P .S.I.G. Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring T ool, Large 3.6 6.0 8. 4 24 Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3. 9 3.25 9.1 13 Screwdriver , #2 to #6 Screw 1.8 3. 0 4 .2 12 Rammers, Medium 5.1 8. 5 1 1 .9 34[...]

  • Page 73

    OM-4409 Page 69 SECTION 16 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 16-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pro[...]

  • Page 74

    OM-4409 Page 70 16-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.[...]

  • Page 75

    OM-4409 Page 71 16-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

  • Page 76

    OM-4409 Page 72 16-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 3[...]

  • Page 77

    OM-4409 Page 73 16-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not li[...]

  • Page 78

    OM-4409 Page 74 16-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this e[...]

  • Page 79

    OM-4409 Page 75 16-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 4[...]

  • Page 80

    OM-4409 Page 76 SECTION 17 − SELECTING AND PREP ARING A TUNGSTEN FOR DC OR AC WELDING gtaw_Phase_2007 − 04 ! Whenever possible and practical, use DC weld output instead of AC weld output. 17-1. Selecting T ungsten Electrode ( Wear Clean gloves T o Prevent Contamination Of T ungsten ) Amperage Range - Gas T ype ♦ - Polarity Electrode Diameter [...]

  • Page 81

    OM-4409 Page 77 SECTION 18 − GUIDELINES FOR TIG WELDING (GT A W) gtaw 7/2006 18-1. Positioning The T orch Ref. ST-161 892 ! Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) a t the grinder or wear an approved respirator . Read MSDS for safety inf[...]

  • Page 82

    OM-4409 Page 78 18-2. T orch Movement During Welding ST-162 002-B T ungsten Without Filler Rod T ungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° W elding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove rod W elding direction 15 °[...]

  • Page 83

    OM-4409 Page 79 18-3. Positioning T orch T ungsten For V arious Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint[...]

  • Page 84

    OM-4409 Page 80 SECTION 19 − P ARTS LIST  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 123 124 125 126 127 128 129 130 131 − Figure 19-2 132 133 15 134 135 136 137 138 139 140 141 142 143 144 − Figure 19-3 28 29 30 31 32 33 34 35 145 146 − Figure 19-5 147 148[...]

  • Page 85

    OM-4409 Page 81 803 324 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 74 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 11 0 111 1 12 − Figure 19-4 11 3 11 4 11 5 11 6 11 7 11 8 11 9 120 121 122 149 150 151[...]

  • Page 86

    OM-4409 Page 82 Description Part No. Dia. Mkgs. Item No. Figure 19-1. Main Assembly Quantity 1 189824 Panel, Gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 189828 Panel, Engine Side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 87

    OM-4409 Page 83 Description Part No. Dia. Mkgs. Item No. Figure 19-1. Main Assembly (Continued) Quantity 48 224265 Label, Warning Hot Exhaust Parts Do Not T ouch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 213895 Manifold, Exhaust Muffler Bf4m201 1 Deutz 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 88

    OM-4409 Page 84 Description Part No. Dia. Mkgs. Item No. Figure 19-1. Main Assembly (Continued) Quantity 199505 Hose Assy , Oil Drain 32.000 Lg (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 165271 V alve, Oil Drain 3/8 − 18 Nptf 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 89

    OM-4409 Page 85 Description Part No. Dia. Mkgs. Item No. Figure 19-1. Main Assembly Quantity 129 R3 189699 Resistor , WW T ap 375 W 10 Ohm W/Mtg Bkt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 218086 Bracket, Holddown Fuel T ank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 90

    OM-4409 Page 86 803 325-D 8 1 2 3 4 5 6 7 10 11 12 14 15 17 18 19 21 22 26 25 23 27 13 9 20 16 24 Figure 19-2. Control Box Assembly Description Part No. Dia. Mkgs. Item No. Figure 19-2. Control Box Assembly − (Figure 19-1 Item 131) Quantity 1 F1, F2 085874 Fuse, Mintr Cer Slo − blo 10. Amp 250 V olt 2 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 91

    OM-4409 Page 87 Description Part No. Dia. Mkgs. Item No. Figure 19-2. Control Box Assembly (Continued) Quantity 23 217823 Label, Layout Control Box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 201079 Cover , Control Box 1 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 92

    OM-4409 Page 88  Hardware is common and not available unless listed. 11 30 10 7 13 28 26 55 44 42 53 52 51 49 50 45 46 48 47 32 39 40 41 38 37 35 34 31 43 33 29 27 57 56 58 59 1 6 5 8 9 2 4 3 18 23 19 24 25 21 22 20 16 15 14 17 12 36 54 803 326-A Figure 19-3. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 19-3. Panel, [...]

  • Page 93

    OM-4409 Page 89 Description Part No. Dia. Mkgs. Item No. Figure 19-3. Panel, Front w/Components (Continued) Quantity 206809 Harness, Weld Control (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 S6 193234 Switch, Rotary 6 Position Gold Contacts 1 . . . . . . . . . . . . .[...]

  • Page 94

    OM-4409 Page 90 Description Part No. Dia. Mkgs. Item No. Figure 19-3. Panel, Front w/Components (Continued) Quantity 41 ♦ 059773 Switch, Handle (Polarity/AC Switch) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ♦ 010647 Pin (Polarity/AC Switch) 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 95

    OM-4409 Page 91 803 327 33 32 31 1 2 4 3 5 30 28 29 26 27 6 25 24 8 7 9 21 23 22 10 12 13 11 20 19 15 14 18 16 17 Figure 19-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 19-4. Generator (Figure 19-1 Item 1 12) Quantity 1 132053 Screw, 375 − 16x1.50 Hex Hd − pln Gr5 Pld 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 96

    OM-4409 Page 92 Description Part No. Dia. Mkgs. Item No. Figure 19-4. Generator (Continued) Quantity 23 172555 Screw, M10 − 1.5x 50 Hex Hd − pln 8.8 Pld 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 602159 Screw, 312 − 18x .75 Hexwhd.66d Stl Pld Slf fmg T ap − rw 6 . . . . . . . . . . . . .[...]

  • Page 97

    OM-4409 Page 93  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 19-5. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 19-5. Main Rectifier Assembly (Figure 19-1 Item 146) Quantity SR3 215910 Rectifier , environmental (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 98

    OM-4409 Page 94  Hardware is common and not available unless listed. 803 328 − G 45 9 78 77 76 75 71 4 1 2 3 4 5 6 7 8 9 10 11 12 13 9 14 11 15 16 17 18 19 20 22 23 24 25 26 27 4 29 31 32 33 34 70 69 68 35 37 38 36 39 40 42 62 63 64 65 66 61 28 60 59 56 55 43 44 45 46 47 48 49 54 50 67 58 53 57 41 6 74 72 81 82 83 79 80 84 86 85 73 26 87 88 21[...]

  • Page 99

    OM-4409 Page 95 Description Part No. Dia. Mkgs. Item No. Figure 19-6. Air Compressor Assembly (Figure 19-1 Item 78) Quantity 1 206607 V alve, Ball 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 210523 Ftg, Flrd Stl T ube End/Female Pipe End 3/4 1 . [...]

  • Page 100

    OM-4409 Page 96 Description Part No. Dia. Mkgs. Item No. Figure 19-5. Air Compressor Assembly (Continued) Quantity 53 206698 Plate, Mtg Compressor T o Bracket 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 218305 V alve, Inlet Unloader 90dg 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 101

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 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[...]

  • Page 102

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − [...]