Miller Electric OM-4409 Owner's Manual

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

OM-4409 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4409 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4409 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4409 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineCheck engine belt Check Air

OM-4409 Page 10SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRatedWeldingOutputMaximumOpen-CircuitVol

OM-4409 Page 114-4. 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 124-5. Stick And MIG Volt-Ampere Curves208 135 / 203 415 / 208 956The volt-ampere curve shows theminimum and maximum voltageand amperage

OM-4409 Page 134-6. TIG Volt-Ampere Curves208 136 / 208 957The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

OM-4409 Page 144-7. 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 154-9. Generator AC Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

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

OM-4409 Page 164-10. Optional 3-Phase Generator Power Curves197 472 / 197 473The ac power curves show the gen-erator power available in amperesat the

OM-4409 Page 174-11. Air Compressor Output Curve208 955The air output curve shows the vol-ume and pressure of air availablefrom the air compressor.020

OM-4409 Page 184-13. Manufacturing Rating Label

OM-4409 Page 19SECTION 5 − INSTALLATIONinstall3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transpo

OM-4409 Page 205-2. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on bas

OM-4409 Page 215-3. Installing Optional Spark Arrestor MufflerTools Needed:803 230 Stop engine and let cool.1 Spark Arrestor Muffler2 Double-Flanged

OM-4409 Page 225-4. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber

OM-4409 Page 235-5. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:802 168-E / Ref. 202 705 / 802 313 / S-0756-C Reinst

OM-4409 Page 245-7. Engine/Compressor Prestart Checks Check all engine/compressor fluidsdaily.Engine must be cold and on a level surface.Unit is ship

OM-4409 Page 255-8. Connecting To Weld Output Terminals803 231Tools Needed:3/4 in Stop engine.1 Positive (+) Weld Output Terminal2 Negative (−) Weld

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

OM-4409 Page 265-9. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4409 Page 275-10. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbreaker CB5.24 VOL

OM-4409 Page 285-11. Connecting To The Air Compressor Air pressure is present at air shutoffvalve whenever Air Pressure Gaugeon front panel indicates

OM-4409 Page 29Notes

OM-4409 Page 30SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Controls (See Section 6-2)803 229 / 206 467-A13172111 15 1612 6574831491810

OM-4409 Page 316-2. Description Of Controls (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to energize starting aid for cold

OM-4409 Page 326-3. Process/Contactor Switch217 638-A11 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswitch is

OM-4409 Page 336-4. Using Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Section 5-10).0774 / R

OM-4409 Page 34SECTION 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 357-2. Connecting To Optional AC Power PlantRef. 197 399 / 802 332-B Do not weld while using optionalac power plant. Place Process/Cont

TABLE OF CONTENTSSECTION 7 − OPERATING AUXILIARY EQUIPMENT 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4409 Page 367-3. 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 37SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER8-1. Battery Charge Controls1 Output Selector Switch Do not switch under load. Stop engi

OM-4409 Page 388-3. Battery Charge Cable Connections Stop engine. Do not charge or jump start a batterywhich has loose terminals or oneshowing damag

OM-4409 Page 398-4. Battery Charging ProcedureStop Engine.Connect Cables (ObserveCorrect Polarity).Set Output Selector Switch ToVoltage Of Battery Bei

OM-4409 Page 408-5. Jump Starting ProcedureConnect Cables (ObserveCorrect Polarity).Set Output Selector Switch ToVoltage Of Battery BeingCharged (12 O

OM-4409 Page 41SECTION 9 − ENGINE/GENERATOR MAINTENANCE9-1. Engine Maintenance Label

OM-4409 Page 42 Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.Note9-2. Routine Engine/

OM-4409 Page 43Every 1000 hService WeldingGenerator BrushesAnd Slip Rings.Service More OftenIn Dirty Conditions.*Change EngineFuel Filters.See Section

OM-4409 Page 449-4. Servicing Engine Air Cleaneraircleaner1 9/00 − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B Stop engine. Do not run engine with

OM-4409 Page 459-5. Inspecting/Cleaning Optional Spark Arrestor Muffler803 228 / 803 230 Stop engine and let cool.1 Spark Arrestor Muffler2 Cleanout

OM-4409 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow thes

OM-4409 Page 469-6. Adjusting Engine Speed803 228 / 802 313-A Stop engine and let cool.Engine speed is factory set andshould not require adjustment.

OM-4409 Page 479-7. Servicing Engine Fuel And Lubrication Systems 803 228 Stop engine and let cool. After servicing, start engine andcheck for fuel

OM-4409 Page 489-8. Engine/Generator Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates a moreserious proble

OM-4409 Page 49SECTION 10 − AIR COMPRESSOR MAINTENANCEUse only genuine Ingersoll Rand compressor oil and filters to maintain3-year warranty on air com

OM-4409 Page 50 Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.Note10-2. Routine Air Com

OM-4409 Page 5110-3. Servicing Compressor Air Cleaneraircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B Stop engine. Do not run air c

OM-4409 Page 5210-4. Compressor Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates a moreserious problem exi

OM-4409 Page 5310-5. 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 5410-6. Adjusting Compressor Air Pressure803 228Tools Needed:Check compressor air pressure usingair pressure gauge known to be accu-rate.

OM-4409 Page 55SECTION 11 − TROUBLESHOOTING11-1. Troubleshooting TablesA. WeldingTrouble RemedyNo weld output; generator power outputokay at ac recept

OM-4409 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4409 Page 56Trouble RemedyConstant speed wire feeder does notwork.Reset circuit breaker(s) CB5 and CB13 (see Section 9-8).Check and secure connecti

OM-4409 Page 57D. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4409 Page 58Trouble 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 59SECTION 12 − AIR COMPRESSOR DIAGRAM209 059-AFigure 12-1. Circuit Diagram For Air Compressor

OM-4409 Page 60Figure 13-1. Circuit Diagram For Welding Generator

OM-4409 Page 61221 915−A

OM-4409 Page 62SECTION 13 − RUN-IN PROCEDURErun_in1 8/0113-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4409 Page 6313-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4409 Page 6413-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4409 Page 65SECTION 14 − AIR COMPRESSOR TABLES14-1. Flow Of Free Air (CFM) Through Orifices Of Various DiametersGauge Pressure (psi)Orifice Diamete

OM-4409 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4409 Page 6614-2. 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 67SECTION 15 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4409 Page 6815-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4409 Page 6915-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4409 Page 7015-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4409 Page 7115-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4409 Page 7215-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4409 Page 7315-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4409 Page 74SECTION 16 − SELECTING AND PREPARINGTUNGSTEN ELECTRODEgtaw 7/97For additional information, see your distributor for a handbook on the G

OM-4409 Page 7516-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) WeldingRef. S-01611 Tungsten Electrode2 Balled End Understand and foll

OM-4409 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4409 Page 76SECTION 17 − GUIDELINES FOR TIG WELDING (GTAW)17-1. Positioning The TorchST-161 892 Weld current can damageelectronic parts in vehicle

OM-4409 Page 7717-3. 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 78SECTION 18 − PARTS LIST Hardware is common and notavailable unless listed. 1234 56789 1011 121314 1516171819 202122 232425 26 27123 12

OM-4409 Page 79803 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 80DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-1. Main AssemblyQuantity1 189824 Panel, Gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4409 Page 81DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-1. Main Assembly (Continued)Quantity48 176230 Label, Hot Exhaust Parts Do Not Touch 1. . .

OM-4409 Page 82DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-1. Main Assembly (Continued)Quantity199505 Hose Assy, Oil Drain 32.000 Lg (includes) 1. . .

OM-4409 Page 83DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-1. Main AssemblyQuantity129 R3 189699 Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt 1. . . . .

OM-4409 Page 84803 325-B121234511619232118172481391014201615722252126Figure 18-2. Control Box AssemblyDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-2. C

OM-4409 Page 85DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-2. Control Box Assembly (Continued)Quantity217815 Harness, Engine Deutz Bf4m2011 (includes)

OM-4409 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez

OM-4409 Page 86 Hardware is common andnot available unless listed.11301071328265544425352514950454648473239404138373534314333292757565859165892431823

OM-4409 Page 87DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-3. Panel, Front w/Components (Continued)Quantity206809 Harness, Weld Control (includes) 1.

OM-4409 Page 88DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-3. Panel, Front w/Components (Continued)Quantity41 ♦059773 Switch, Handle (Polarity/AC Swi

OM-4409 Page 89803 327333231124353028292627625248792123221012131120191514181617Figure 18-4. GeneratorDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-4. Ge

OM-4409 Page 90DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-4. Generator (Continued)Quantity23 172555 Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld 6. . . .

OM-4409 Page 91 Hardware is common andnot available unless listed.802 279-A123465789Figure 18-5. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4409 Page 92 Hardware is common andnot available unless listed.803 328−E45978777675714123456789101112139141115161718192022232425262742931323334706

OM-4409 Page 93DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-6. Air Compressor Assembly (Figure 18-1 Item 78)Quantity1 206607 Valve, Ball 1. . . . . .

OM-4409 Page 94DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 18-5. Air Compressor Assembly (Continued)Quantity53 206698 Plate, Mtg Compressor To Bracket 1

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa