Miller Electric OM-4409 User Manual

Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Engine Driven Welding Generator And
Air Compressor
OM-4409 206 941V
2007−05
TIG (GTAW) Welding
With Optional Equipment:
Battery Charging
Big Blue Air Pak
®
Visit our website at
www.MillerWelds.com
File: Engine Drive

Miller Electric OM-4409 Specifications

General

Brand	Miller Electric
Model	OM-4409
Category	Welding System
Language	English

Summary

Safety Precautions

Arc Welding Hazards

Details hazards associated with arc welding processes and necessary precautions.

General Hazards

Covers hazards including fumes, gas, arc rays, fire, noise, fields, and cylinders.

Engine Hazards

Covers various hazards related to the engine, including explosion, fuel, moving parts, and hot parts.

Compressed Air Hazards

Covers hazards related to compressed air, including breathing, pressure, and whipping hoses.

Specifications

Weld, Power, And Engine Specifications

Provides detailed specifications for welding output, generator power, and engine.

Duty Cycle And Overheating

Installation

Installing Welding Generator

Details procedures for securely mounting and grounding the welding generator.

Mounting Welding Generator

Explains methods for mounting the generator unit, including using brackets or welding.

Connecting The Battery

Details the correct procedure for connecting the battery, emphasizing negative cable last.

Engine/Compressor Prestart Checks

Outlines essential checks for the engine and compressor before starting.

Connecting To Weld Output Terminals

Provides instructions for correctly connecting weld cables to output terminals.

Connecting To The Air Compressor

Details how to connect the air compressor and ensure proper operation.

Operating The Welding Generator

Controls Overview

Identifies and locates the various controls on the generator's front panel.

Description Of Controls

Provides detailed descriptions of each control and gauge on the generator.

Engine Starting Controls

Explains the function of engine starting controls like the Starting Aid and Engine Control switch.

Weld Controls

Details the operation of weld controls like the Ampere Range switch and Voltage/Amperage Adjust.

Air Compressor Controls

Explains how to operate the air compressor switch and its associated functions.

Process/Contactor Switch

Explains how to use the Process/Contactor switch to select weld processes and control output.

Using Remote Voltage/Amperage Control

Guides users on how to use remote controls for voltage and amperage adjustment.

Operating Optional Battery Charger

Battery Charge Cable Connections

Details the correct procedure for connecting battery charge cables to the unit and battery.

Battery Charging Procedure

Provides a step-by-step guide for performing the battery charging procedure.

Jump Starting Procedure

Outlines the steps for jump-starting a vehicle using the generator.

Engine/Generator Maintenance

Routine Engine/Generator Maintenance

Presents a maintenance schedule for the engine and generator based on operating hours.

Servicing Engine Air Cleaner

Details the procedure for cleaning or replacing the engine air cleaner element.

Servicing Engine Fuel And Lubrication Systems

Covers servicing procedures for the engine's fuel and lubrication systems, including oil and filters.

Engine/Generator Overload Protection

Identifies various circuit breakers and protectors for engine and generator overload.

Air Compressor Maintenance

Routine Air Compressor Maintenance

Presents a maintenance schedule for the air compressor based on operating hours.

Servicing Compressor Air Cleaner

Details the procedure for servicing the compressor's air cleaner element.

Servicing Air Compressor

Troubleshooting

Troubleshooting Tables

Circuit Diagram

Circuit Diagram For Welding Generator

Run-In Procedure

Run-In Procedure Using Load Bank

Run-In Procedure Using Resistance Grid

Generator Power Guidelines

Grounding Generator To Truck Or Trailer Frame

Selecting and Preparing Tungsten

Selecting Tungsten Electrode

Preparing Tungsten Electrode For Welding

Guidelines for TIG Welding (GTAW)

Positioning The Torch