Miller Electric OM-4409 manual Routine Engine/Generator Maintenance

Page 48

9-2. Routine Engine/Generator Maintenance

.See Section 10 for air compressor maintenance information.

 

 

 

 

! Stop engine before maintaining.

 

 

 

Recycle engine

. See Engine Manual and Maintenance Label

 

 

 

fluids.

for important start-up, service, and storage

 

 

 

information. Service engine more often if

 

 

 

 

 

 

 

 

used in severe conditions.

n = Check

Z = Change

~ = Clean

l = Replace

Reference

* To be done by Factory Authorized Service Agent

 

 

Every

FUEL

 

 

 

Section 5-7,

8

 

 

 

9-6

WATER

 

 

 

Hours

 

 

 

 

 

 

 

 

 

 

n Fuel/Water Separator

n Fuel Level

n Oil Level

~ Oil, Fuel Spills

 

Every

 

 

 

 

 

50

 

 

 

 

 

Hours

 

 

 

 

 

 

~ Weld Terminals

 

 

 

 

Every

 

 

 

 

Section 9-4

100

 

 

 

 

 

Hours

 

 

 

 

 

 

~ Battery Terminals

n Air Cleaner Hoses

n Air Cleaner Element

 

 

Every

 

 

 

 

Engine

250

 

1/2 in.

 

 

Manual,

Hours

 

(13 mm)

 

 

Section 9-5

 

 

 

 

 

l Unreadable Labels

n Fan Belt Tension

~ Cooling System

n~Spark Arrestor

 

Every

 

 

 

 

 

500

 

 

 

 

 

Hours

 

 

 

 

 

 

nl Weld Cables

Z Oil

Z Oil Filter

 

 

Every

 

 

 

FUEL

Section 9-6,

1000

 

OR

 

9-3and

Hours

 

 

 

Engine

 

 

 

 

 

 

 

 

SLUDGE

Manual

 

 

 

 

 

 

Z Fuel Filter

~ Inside Unit

nValve Clearance*

~ Drain Sludge

 

 

n~ Slip Rings*

 

 

 

 

 

nl Brushes*

 

 

 

 

Every

 

 

 

 

 

3000

 

 

 

 

 

Hours

 

 

 

 

 

 

~ Injectors*

 

 

 

 

Every

 

 

 

 

 

6000

 

 

 

 

 

Hours

 

 

 

 

 

or 5

 

 

 

 

 

Years

 

 

 

 

 

 

nl Engine Timing Belt

 

 

 

 

OM-4409 Page 44

 

 

 

 

Page 47 Page 49
Image 48
Page 47 Page 49
Contents OM-4409206 ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Operating Optional Battery Charger − TroubleshootingTroubleshooting Tables − Parts ListSymbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicauxSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsAir Compressor Specifications Sound Level TableDimensions, Weights, And Operating Angles WeightLifting Eye Weight Rating DC Stick Mode AC Stick Mode OptionalMIG Mode Stick And MIG Volt-Ampere CurvesDC TIG Mode AC TIG Mode OptionalTIG Volt-Ampere Curves Fuel Consumption Duty Cycle And Overheating100% Duty Cycle At 500 Amperes 40% Duty Cycle At 600 AmperesGenerator AC Power Curve Optional 3-Phase Generator Power Curves 12 kVA/kW Single-Phase AC Output No Weld Load20 kVA/kW Three-Phase AC Output No Weld Load Optional Battery Charging Output Curve Air Compressor Output CurveManufacturing Rating Label − Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Optional Spark Arrestor Muffler Mount the muffler with the clean- out plug to the outsideStop engine and let cool Be sure to tighten rain cap mounting screwActivating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells Reinstall cover after connecting batteryUsing The Optional Battery Disconnect Switch Switch may be locked using a customer-supplied padlockStop engine Engine/Compressor Prestart Checks Connecting To Weld Output Terminals Stick And TIG WeldingMIG And Fcaw Welding Connecting to weld Output terminals Selecting Weld Cable Sizes150 ft 200 ft 250 ft Connecting To Remote 14 Receptacle RC14 SocketConnecting To The Air Compressor Open Position Closed Position− Operating the Welding Generator Controls See SectionDescription Of Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsUsing Remote Voltage/Amperage Control Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en Is working properlyConnecting To Optional AC Power Plant Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current Output Selector SwitchBattery Charge Cable Connections Battery Charging Procedure To control battery charging output using aJump Starting Procedure Charge battery for 10 minutes before jump starting batteryConnect Remote Or Control Device Momentary-On Switch Cables− ENGINE/GENERATOR Maintenance Engine Maintenance LabelRoutine Engine/Generator Maintenance Material Thickness Reference Chart Checking Generator BrushesServicing Engine Air Cleaner Air cleaner primary element canTo clean air filter Optional Keep nozzle 2 in 51 mm from elementInspecting/Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededAdjusting Engine Speed Do not set engine speed higher than specifiedServicing Engine Fuel And Lubrication Systems Wipe up spilled fuelTo change oil and filter To drain water from fuel systemEngine/Generator Overload Protection − AIR Compressor Maintenance Air Compressor Maintenance LabelRoutine Air Compressor Maintenance Servicing Compressor Air Cleaner Compressor Air CleanerRemove engine air cleaner cover Reinstall primary element and cover dust ejector downCompressor Overload Protection See -8for engine/genera- tor overload protectionServicing Air Compressor To change compressor oil and filterEngine oil drain and compressor oil To replace air/oil separatorAdjusting Compressor Air Pressure − Troubleshooting Troubleshooting TablesWelding Standard Generator Power Optional AC Power PlantEngine Optional Battery Charging Air Compressor− AIR Compressor Diagram Circuit Diagram For Air Compressor− Circuit Diagram Circuit Diagram For Welding Generator221 915−C − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank From flammablesOutput and do not exceed duty Cycle or equipment damage mayRun-In Procedure Using Resistance Grid − AIR Compressor Tables Flow Of Free Air CFM Through Orifices Of Various DiametersSec 15 sec 21 sec − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Preparing Tungsten For DC Electrode Negative Dcen Welding Preparing Tungsten For AC WeldingAmperage Range Gas Type Polarity − Guidelines for TIG Welding Gtaw Positioning The TorchTorch Movement During Welding Tungsten Without Filler RodWelding direction Form pool Tilt torch Tungsten With Filler RodPositioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead Joint Lap Joint Corner Joint− Parts List Hardware is common and not available unless listed133 148 147 126121 109 120 122 108 102 103 105 106 107 7273 Dia Part Description Quantity Mkgs 224265 199505 CT1 21 22 C1/D1CB11,CB12,CB13 Hardware is common Not available unless listed 2724 40 39CB2 Fuel Generator Generator -1Item172555 Main Rectifier Assembly Air Compressor Assembly 10 9 1516 8281 7371Air Compressor Assembly -1Item Clutch Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

OM-4409 specifications

The Miller Electric OM-4409 is a remarkable welding machine designed for both professional welders and enthusiastic hobbyists. Known for its reliability and efficiency, the OM-4409 stands out in the industrial landscape due to its advanced features and innovative technologies.

One of the main features of the OM-4409 is its impressive power output. With a rated output of 400 amps, it is capable of tackling a variety of welding applications, including MIG, TIG, and stick welding. This versatility allows users to switch between welding processes depending on the project requirements while ensuring consistent quality and performance.

The machine incorporates advanced inverter technology, which enhances its overall efficiency. Inverter technology allows for a compact design without sacrificing performance. The OM-4409 weighs significantly less than traditional transformer-based machines, making it more portable and easier to transport. Additionally, the inverter technology ensures that energy consumption is kept to a minimum, reducing operational costs.

Another notable characteristic of the Miller Electric OM-4409 is its user-friendly interface. The intuitive control panel provides easy access to settings and adjustments, allowing welders to fine-tune the machine to their specific needs. The digital display shows crucial parameters such as voltage, amperage, and wire feed speed, enabling welders to monitor their progress in real-time effectively.

Safety is paramount in industrial applications, and the OM-4409 does not disappoint. It is equipped with advanced safety features, including thermal overload protection and fault indication systems. These features ensure that the machine operates within safe limits, protecting both the user and the equipment.

The OM-4409 also boasts a robust build quality, designed to withstand the rigors of daily use in demanding environments. Its durable construction ensures longevity, minimizing maintenance and downtime.

In summary, the Miller Electric OM-4409 welding machine is a powerhouse that combines power, efficiency, and user-friendliness. With its inverter technology, versatility across various welding processes, advanced safety features, and robust design, it represents an excellent investment for any welding professional looking to enhance their capabilities. Whether for heavy-duty industrial applications or intricate metalwork, the OM-4409 delivers unmatched performance and reliability.
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