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OM-278215E 2018−04 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 400 Pro ® Kubota And Mitsubishi ® Big Blue 400 PipePro ® Mitsubishi For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com File: Engine Drive From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard. 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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 2017−06 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. AC Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Kubota Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Mitsubishi Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Engine Fuel And Coolant Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 3 4 6 6 6 7 7 7 9 10 11 13 13 13 14 14 15 17 17 17 17 17 18 19 20 20 21 21 22 22 23 23 24 24 25 26 26 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as necessary. For more information go to www.P65warnings.ca.gov/diesel. TABLE OF CONTENTS 5-11. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Connecting To Remote Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Dynamic Dig Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8. Lift-Arc TIG With Auto-Stop And Auto-Crater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Voltage/Amperage Control With 14-Pin Remote Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10. Operating Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14. Associating ArcReach Devices (ArcReach Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Mitsubishi Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Kubota Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Checking Generator Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8. Mitsubishi Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9. Kubota Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13. Maintaining Stainless Steel (Models With Optional Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPLETE PARTS LIST − Available at www.MillerWelds.com WARRANTY 27 27 28 28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 41 42 43 43 44 45 46 47 47 48 49 49 51 52 54 54 54 55 57 57 58 62 62 63 64 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 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 explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling. Use AC output ONLY if required for the welding process. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first − double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment. Test GFCI receptacles at high speed. If AC output is required, use remote output control if present on unit. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER stopping engine. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Stop engine on inverter and discharge input capacitors according to instructions in Manual before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. OM-278215 Page 1 FLYING METAL or DIRT can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. FUMES AND hazardous. GASES can be Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc. Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. OM-278215 Page 2 Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder — explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Engine Hazards BATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables, battery charging cables (if applicable), or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose. Observe correct polarity (+ and −) on batteries. Disconnect negative (−) cable first and connect it last. Keep sparks, flames, cigarettes, and other ignition sources away from batteries. Batteries produce explosive gases during normal operation and when being charged. Follow battery manufacturer’s instructions when working on or near a battery. See Battery Service Manual (listed in Safety Standards) for additional information. FUEL can cause fire or explosion. Stop engine and let it cool off before checking or adding fuel. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank — allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. Always keep nozzle in contact with tank when fueling. MOVING PARTS can injure. Keep away from moving parts such as fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (−) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts. Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. Block flywheel so that it will not turn while working on generator components. EXHAUST SPARKS can cause fire. Do not let engine exhaust sparks cause fire. Use approved engine exhaust spark arrestor in required areas — see applicable codes. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap. Turn cap slightly and let pressure escape slowly before completely removing cap. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. BATTERY ACID can BURN SKIN and EYES. Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water. ENGINE HEAT can cause fire. Do not locate unit on, over, or near combustible surfaces or flammables. Keep exhaust and exhaust pipes way from flammables. 1-4. Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill. Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, operate, and service this unit according to its Owner’s Manual, industry standards, and national, state, and local codes. Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air system. Design compressed air system so failure of any component will not put people or property at risk. Before working on compressed air system, turn off and lockout/ tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer’s instructions. Do not modify or alter compressor or manufacturer-supplied equipment. Do not disconnect, disable, or override any safety equipment in the compressed air system. Use only components and accessories approved by the manufacturer. Keep away from potential pinch points or crush points created by equipment connected to the compressed air system. Do not work under or around any equipment that is supported only by air pressure. Properly support equipment by mechanical means. OM-278215 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby. COMPRESSED AIR can injure or kill. Before working on compressed air system, turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Relieve pressure before disconnecting or connecting air lines. Check compressed air system components and all connections and hoses for damage, leaks, and wear before operating unit. Do not direct air stream toward self or others. Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and a cap when working on compressed air system. Use soapy water or an ultrasonic detector to search for leaks−−never use bare hands. Do not use equipment if leaks are found. Reinstall doors, panels, covers, or guards when servicing is finished and before starting unit. If ANY air is injected into the skin or body seek medical help immediately. BREATHING COMPRESSED AIR can injure or kill. Do not use compressed air for breathing. Use only for cutting, gouging, and tools. TRAPPED AIR PRESSURE AND WHIPPING HOSES can injure. Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap. MOVING PARTS can injure. Keep away from moving parts such as fans, belts and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Keep hands, hair, loose clothing, and tools away from moving parts. Before working on compressed air system, turn off and lockout/ tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. HOT PARTS can burn. Do not touch hot compressor or air system parts. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. 1-5. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. Use lifting eye to lift unit and properly installed accessories only, NOT gas cylinders. Do not exceed maximum lift eye weight rating (see Specifications). Use correct procedures and equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. OM-278215 Page 4 OVERHEATING can damage motors. Turn off or unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. MOVING PARTS can injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. BATTERY CHARGING OUTPUT and BATTERY EXPLOSION can injure. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. Battery charging not present on all models. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables, battery charging cables (if applicable), or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. Observe correct polarity (+ and −) on batteries. Disconnect negative (−) cable first and connect it last. Keep sparks, flames, cigarettes, and other ignition sources away from batteries. Batteries produce explosive gases during normal operation and when being charged. Follow battery manufacturer’s instructions when working on or near a battery. See Battery Service Manual (listed in Safety Standards) for additional information. Have only qualified persons do battery charging work. If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc, make sure all accessories are off. Charge lead-acid batteries only. Do not use battery charger to supply power to an extra-low-voltage electrical system or to charge dry cell batteries. Do not charge a frozen battery. Do not use damaged charging cables. Do not charge batteries in a closed area or where ventilation is restricted. Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover. Before charging battery, select correct charger voltage to match battery voltage. Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each other. Keep charging cables away from vehicle hood, door, or moving parts. HIGH PRESSURE FLUIDS can injure or kill. Engine fuel system components can be under high pressure. Before working on fuel system, turn off engine to release pressure. If any fluid is injected into the skin or body seek medical help immediately. TILTING OF TRAILER can injure. Use tongue jack or blocks to support weight. Properly install welding generator onto trailer according to instructions supplied with trailer. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION 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 correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-278215 Page 5 1-6. California Proposition 65 Warnings For Diesel Engines: WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov. WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well−ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as necessary. For more information, go to www.P65Warnings.ca.gov/diesel. 1-7. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). For Standards regulating hydraulic systems, contact the National Fluid Power Association, 6737 West Washington St., Suite 2350, Milwaukee, WI 53214 (phone: (414) 778-3344, website: www.nfpa.com). Battery Service Manual, Battery Council International, 330 North Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074, website: www.batterycouncil.org). 1-8. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. OM-278215 Page 6 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. AVIS − Indique des déclarations pas en relation avec des blessures personnelles. Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-7. Veuillez lire et respecter toutes ces normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec succès sa capacité à résoudre les problèmes liés à la tâche, le travail ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents. Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. UN CHOC ÉLECTRIQUE peut tuer. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger. Ne jamais toucher les pièces électriques sous tension. Porter des gants et des vêtements de protection secs ne comportant pas de trous. S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. Ne pas utiliser de sortie de soudage CA dans des zones humides ou confinées ou s’il y a un risque de chute. Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort. Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Ne pas toucher aux portes−électrodes qui sont raccordés à deux machines à souder en même temps, car cela entraîne la présence d’une tension de circuit−ouvert double. Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. OM-278215 Page 7 Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé. Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coupé. Arrêtez le moteur sur l’onduleur et déchargez les condensateurs d’entrée conformément aux instructions du manuel avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Eloigner votre tête des fumées. Ne pas respirer les fumées. À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquelles est exposé le personnel. Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. OM-278215 Page 8 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz comprimé en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu ils n aient été préparés correctement conformément à AWS F4.1 et AWS A6.0 (voir les Normes de Sécurité). Ne pas souder là où l’air ambiant pourrait contenir des poussières, gaz ou émanations inflammables (vapeur d’essence, par exemple). Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Porter des protections approuvés pour les oreilles si le niveau sonore est trop élevé. Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne. Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille. Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les bouteilles. Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers existant en relation avec le moteur L’EXPLOSION DE LA BATTERIE peut provoquer des blessures. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher des câbles de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage. Observer la polarité correcte (+ et −) sur les batteries. Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu. Les sources d’étincelles, flammes nues, cigarettes et autres sources d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge. Suivre les instructions du fabricant de la batterie lors d’opérations sur une batterie ou à proximité de celle−ci. Voir le manuel de service de batterie (indiqué dans Normes de sécurité) pour plus d’informations. LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein. Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur. Jeter les chiffons dans un récipient ignifuge. Toujours garder le pistolet en contact avec le réservoir lors du remplissage. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors. Maintenir fermés et verrouillés les portes, recouvrements et dispositifs de protection. panneaux, Arrêter le moteur avant d’installer ou brancher l’appareil. Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (−) de batterie de la borne. OM-278215 Page 9 Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Remettre en place les portes, panneaux, recouvrements ou dispositifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en route accidentelle du moteur. Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur. LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher des parties chaudes à mains nues. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler. Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisible et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et bouches aération. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas renverser la batterie. Remplacer une batterie endommagée. Rincer immédiatement les yeux et la peau à l’eau. LA CHALEUR DU MOTEUR peut provoquer un incendie. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Tenir à distance les produits inflammables de l’échappement. 2-4. Dangers liés à l’air comprimé Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort. Une installation ou une utilisation incorrecte de cet appareil pourrait conduire à des dégâts matériels ou corporels. Seul un personnel qualifié est autorisé à installer, utiliser et entretenir cet appareil conformément à son manuel d’utilisation, aux normes industrielles et aux codes nationaux, d’état ou locaux. Ne pas dépasser le débit nominal ou la capacité du compresseur ou de tout équipement du circuit d’air comprimé. Concevoir le circuit d’air comprimé de telle sorte que la défaillance d’un composant ne risque pas de provoquer un accident matériel ou corporel. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil fonctionne. Seul un personnel qualifié est autorisé, et appliquant les consignes du fabricant. Ne pas modifier ou altérer le compresseur ou les équipements fournis par le fabricant. Ne pas débrancher, désactiver ou neutraliser les équipements de sécurité du circuit d’air comprimé. Utiliser uniquement des composants et accessoires homologués par le fabricant. Se tenir à l’écart de tout point présentant un danger de pincement ou d’écrasement créé par l’équipement raccordé au circuit d’air comprimé. Ne pas intervenir sous ou autour d’un équipement qui n’est soutenu que par la pression pneumatique. Soutenir l’équipement de façon appropriée par un moyen mécanique. OM-278215 Page 10 MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion. Ne pas découper ou gouger à proximité de produits inflammables. Attention aux risques d’incendie: tenir un extincteur à proximité. L’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Détendre la pression avant de débrancher ou de brancher des canalisations d’air. Avant d’utiliser l’appareil, contrôler les composants du circuit d’air comprimé, les branchements et les flexibles en recherchant tout signe de détérioration, de fuite et d’usure. Ne pas diriger un jet d’air vers soi−même ou vers autrui. Pour intervenir sur un circuit d’air comprimé, porter un équipement de protection tel que des lunettes de sécurité, des gants de cuir, une chemise et un pantalon en tissu résistant, des chaussures montantes et une coiffe. Pour rechercher des fuites, utiliser de l’eau savonneuse ou un détecteur à ultrasons, jamais les mains nues. En cas de détection de fuite, ne pas utiliser l’équipement. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de mettre en marche l’appareil. En cas d’injection d’air dans la peau ou le corps, demander immédiatement une assistance médicale. L’INHALATION D’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort. Ne pas inhaler d’air comprimé. Utiliser l’air comprimé uniquement pour découper ou gouger ainsi que pour l’outillage pneumatique. Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures. Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du compresseur. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Demander seulement à un personnel qualifié d’enlever les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage. Remettre en place les portes, panneaux, recouvrements ou dispositifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher de pièces chaudes du compresseur ou du circuit d’air. Prévoir une période de refroidissement avant d’intervenir sur l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux. 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de produits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. Utiliser l’anneau de levage pour lever l’appareil et les accessoires correctement installées seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton (voir les spécifications). Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94−110) lors du levage manuelle de pièces ou équipements lourds. LE SURCHAUFFEMENT peut endommager le moteur électrique. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures. Porter un écran facial pour protéger le visage et les yeux. Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie − éloigner toute substance inflammable. Les PIÈCES MOBILES peuvent causer des blessures. Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent provoquer des blessures. La recharge de batterie n’existe pas sur tous les modèles. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher des câbles de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage. Observer la polarité correcte (+ et −) sur les batteries. OM-278215 Page 11 Débrancher le câble négatif (−) en premier lieu. Le rebrancher en dernier lieu. Les sources d’étincelles, flammes nues, cigarettes et autres sources d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge. Suivre les instructions du fabricant de la batterie lors d’opérations sur une batterie ou à proximité de celle−ci. Voir le manuel de service de batterie (indiqué dans Normes de sécurité) pour plus d’informations. Les opérations de charge de batterie ne doivent être effectuées que par des personnes qualifiées. Pour enlever la batterie d’un véhicule pour la recharge, débrancher tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour éviter un arc, s’assurer que tous les accessoires sont débranchés. Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit électrique basse tension ou pour charger des batteries sèches. Ne pas charger une batterie gelée. Ne pas utiliser de câbles de charge endommagés. Ne pas charger des batteries dans un espace fermé ou en l’absence d’une ventilation. Ne pas charger une batterie dont les bornes sont desserrées ou présentant une détérioration comme par exemple un boîtier ou un couvercle fissuré. Avant de charger une batterie, sélectionner la tension de charge correspondant à la tension de la batterie. Régler les commandes de charge de batterie sur la position d’arrêt avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas. Ranger les câbles de charge à distance du capot, des portes et des pièces mobiles du véhicule. LES LIQUIDES PRESSURISÉS peuvent blesser ou tuer. Les composants du système d’alimentation peuvent contenir du carburant sous pression élevée. Avant d’intervenir sur le système d’alimentation de carburant, arrêter le moteur pour dépressuriser le système. En cas d’injection de tout liquide sous la peau ou dans le corps, solliciter une aide médicale sur le champ. LES FILS DE SOUDAGE peuvent provoquer des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. Laisser l’équipement refroidir ; respecter le facteur de marche nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. OM-278215 Page 12 UNE REMORQUE QUI BASCULE peut provoquer des blessures. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 2-6. Proposition californienne 65 Avertissements AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction. Pour plus d’informations, consulter www.P65Warnings.ca.gov. Pour les moteurs diesel : AVERTISSEMENT : les gaz d’échappement de moteurs diesel vous exposent à des produits chimiques, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction. Toujours démarrer et faire tourner le moteur dans une zone bien aérée. Si la zone est fermée, diriger l’échappement vers l’extérieur. Ne pas modifier ni altérer le système d’échappement. Ne pas faire tourner le moteur au ralenti, sauf si nécessaire. Pour plus d’informations, consulter www.P65Warnings.ca.gov/ diesel. 2-7. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, auprès du U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet : www.osha.gov). Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414) 778-3344, site web : www.nfpa.com). Manuel de service de batterie, Battery Council International, 330 North Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone : 1-312-245-1074, site Web : www.batterycouncil.org). 2-8. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage: 1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse. 2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber et ne pas entourer les câbles autour de votre corps. 4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. 6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus. 7. Ne pas souder tout en portant la source de soudage ou le dévidoir. En ce qui concerne les implants médicaux : Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. OM-278215 Page 13 Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2017−04 Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual. Safe89 2017−04 Hot muffler and exhaust pipe can cause severe burns. Safe90 2017−04 Welding, cutting, drilling, or grinding on base can cause fire or explosion. Safe91 2017−04 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Safe46 2012−05 Read Owner’s Manual. Read labels on unit. Safe47 2012−05 <12.4 V Read Owner’s Manual for battery maintenance information. / + − 0 - 50 h std + − Safe117 2014−06 During the first 50 hours of operation keep welding load above 200 amperes. Do not weld below 200 amperes of output. Safe54 2017−04 OM-278215 Page 14 Complete Parts List is available at www.MillerWelds.com 50 h std After the first 50 hours of operation, change the engine oil and filter. Safe55 2012−05 Never use generator inside a home or garage, even if doors and windows are open. Safe87 2012−07 Only use generator outside and far away from windows, doors, and vents. Safe88 2012−07 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. A V Amperage Hz Hertz Negative Voltage h Hours Positive Seconds Protective Earth (Ground) Suitable For Welding In An Environment With Increased Risk Of Electric Shock Direct Current (DC) X I2 U2 U0 I n n0 n1 P1max Circuit Breaker Clock, Time Switch Supplementary Protector Hour Meter Output Duty Cycle Rated Welding Current Conventional Load Voltage Rated No-Load Voltage (OCV) Current Rated Load Speed Sound Level Alternating Current (AC) Single Phase Three Phase Engine-Driven 3-Phase Alternator with Rectifier Rated No-Load Speed Contactor On Rated Idle Speed Arc Force (DIG) Maximum Power Consumption Work Connection Off On Increase or Decrease of Quantity (Rotating) Do Not Switch While Welding Remote Read Operator’s Manual Welding (General) OM-278215 Page 15 Complete Parts List is available at www.MillerWelds.com Shielded Metal Arc Welding (SMAW) Run (Fast) Spark Arrestor Gas Metal Arc Welding (GMAW) Engine Start (Engine RPM) Air Filter Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG) Welding Tungsten Inert Gas (TIG) Lift Arc Flux Cored Arc Welding (FCAW) Air Carbon Arc Cutting (CAC-A) Starting Aid (Preheat) Notes OM-278215 Page 16 Engine Stop Engine Oil Fuel Check Air Cleaner Check Injectors/Pump Check Valve Clearance Filter Certified/Trained Mechanic Engine Coolant Arc Control Engine Coolant Temperature USB Engine Engine Temperature Engine Battery (Engine) Push Button Engine Engine Belt Rotating Knob And Push Button Idle (Slow) Manual Cleaning Call for Maintenance Complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Weld, Power, And Engine Specifications This equipment will deliver rated output at an ambient air temperature up to 1045F (405C). Generator Power Rating Engine Kubota V1505 E3BG Water-Cooled, Four-Cylinder 20.2 HP Diesel Engine Mitsubishi Water-Cooled Four-Cylinder 24.7 HP Diesel Engine Welding Mode Weld Output Range Rated Welding Output Maximum Open-Circuit Voltage Fuel Capacity 400 A, 24 Volts DC, 100% Duty Cycle Single-Phase, 10 kVA/kW, 84/42 A, 120/240 VAC, 60 Hz CC/DC 20−400 A CV/DC 14−40 V 350 A, 27 Volts DC, 100% Duty Cycle 11.5 gal 84 (43.5 L) 300 A, 32 Volts DC, 100% Duty Cycle 4-3. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used when welding outside during precipitation unless sheltered. IP23S 2014−06 B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range −40 to 104°F (−40 to 40°C) −4 to 131°F (−20 to 55°C) *Output is derated at temperatures above 104°F (40°C). Temp_2016- 07 4-4. Dimensions, Weights, And Operating Angles Dimensions Height 32 in. (813 mm) 35.89 in. (912 mm) (to top of lift eye) Width 26 in. (660 mm) (mtg. brackets turned in) 28.75 in. (730 mm) (mtg. brackets turned out) ! Do not exceed tilt angles or engine could be damaged or unit could tip. Depth 56.25 in. (1429 mm) ! A 56.25 in. (1429 mm) Do not move or operate unit where it could tip. B 54.25 in. (1378 mm) C 52.25 in. (1327 mm) D 2 in. (51 mm) E 26 in. (660 mm) F 0.885 in. (22 mm) G 27.77 in. (705 mm) H 9/16 in. (14 mm) Dia. 4 Holes G A B C 30° Weight No fuel: Kubota: 950 lb (431 kg) Mitsubishi: 993 (450 kg) With fuel: Kubota: 1032 lb (468 kg) Mitsubishi: 1075 lb (488 kg) 20° H Front Panel End D 30° 20° F E Lifting Eye Weight Rating: 2000 lb (907 kg) Maximum OM-278215 Page 17 Complete Parts List is available at www.MillerWelds.com 4-5. Duty Cycle And Overheating 1 1 100% Duty Cycle Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. This unit is rated for welding at 400 amperes, 24 volts DC continuously. NOTICE − Exceeding duty cycle can damage unit and void warranty. WELD AMPHERES 400 300 200 0 10 20 30 40 50 60 70 80 90 100 % DUTY CYCLE 266 504-A OM-278215 Page 18 Complete Parts List is available at www.MillerWelds.com 4-6. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. A. Stick Mode 100 DC VOLTS 80 60 MIN 300A 40 20 0 0 100 200 300 DC AMPERES 400 500 B. TIG Mode 100 DC VOLTS 80 60 40 MIN 20 300 MAX 0 0 100 200 300 DC AMPERES 400 500 100 200 400 500 C. MIG Mode 60 MAX DC VOLTS 40 20 MIN 0 0 300 DC AMPERES 264 395-A OM-278215 Page 19 Complete Parts List is available at www.MillerWelds.com 4-7. AC Generator Power Curves The AC power curve shows the generator power in amperes. 280 270 260 250 AC VOLTS 240 230 220 210 200 190 180 0 20 40 60 AC AMPERES IN 240V MODE 264 396-A 4-8. Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.00 1.75 U.S. GAL/HR. 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE 250 370-A OM-278215 Page 20 Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. (460 mm) Movement 18 in. (460 mm) 18 in. (460 mm) OR OR 18 in. (460 mm) 18 in. (460 mm) Location/Mounting 2 Welding Unit In Place Bolting Unit In 2 Place 3 4 OR OR Tools Needed: 1 1 9/16 in. Go to MillerWelds.com for more information on truck installations. Movement ! Do not move or operate unit where it could tip. See Section 4-4 for lifting eye rating. Airflow Clearance NOTICE − Do not install unit where air flow is restricted or engine may overheat. Location/Mounting ! Always securely fasten welder/generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. Use cross-supports to adequately support unit and prevent damage to base. 1 Cross-Supports 2 Mounting Brackets (Supplied) Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brackets. 3 1/2 in Bolt And Washer (Minimum − Not Supplied) 4 3/8-16 x 1 in. Screws (Supplied) To Bolt Unit In Place: Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware. Mount unit to truck or trailer with 1/2 in. (12 mm) or larger hardware (not supplied). To Weld Unit In Place: Weld unit to truck or trailer only at the four mounting brackets. OM-278215 Page 21 Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame 1 2 GND/PE 3 rot_grnd2 2018−01 − 800652-D ! Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ! Bed liners, shipping skids, and some running gear insulate the welding generator from the vehicle ! frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. 1 Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire. 2 3 Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact. 5-3. Installing Exhaust Pipe ! Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in. OM-278215 Page 22 Exhaust Pipe3 2010−04 / Ref 803 582 Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery − + Shown with door open and rocker panel removed. Tools Needed: 1/2 in. Conn_Batt2 2014−11 / S-0756-C / 161-002 NOTICE − Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts DC when measured across the battery terminals. ! Connect negative (−) cable last. NOTICE − Wait two minutes after engine shutdown before disconnecting battery or engine controller may be damaged. Battery is accessed through the side door. Connect battery, negative cable last. Close side door. Do not allow the battery cables to touch opposing terminals. When connecting the battery cables attach the positive (+) cable to the positive (+) battery terminal first, followed by negative (−) cable to negative (−) battery terminal. Never start the engine when the cables are loose or poorly connected to the battery terminals. Never disconnect the battery while the engine is running. Never use a quick battery charger to start the engine. Do not charge battery with Engine Control switch On. Always disconnect the negative (−) battery cable before charging battery. 5-5. Kubota Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full OM-278215 Page 23 Complete Parts List is available at www.MillerWelds.com 5-6. Mitsubishi Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full 5-7. Engine General Information Check all engine fluids daily. Engine must be cold and on a level surface. Automatic Shutdown System Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high. This unit has a low oil pressure shut- down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Run-In Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 11. NOTICE − Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Light or no load may cause wetstacking or engine damage. Cold Weather To improve cold weather starting: Use Preheat switch (see Section 6-1). Keep battery in good condition. Store battery in warm area. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 8-3). Use engine block heater if applicable (see Section 6-10). Gen_engine1 2012−04 OM-278215 Page 24 Complete Parts List is available at www.MillerWelds.com 5-8. Engine Fuel And Coolant Prestart Information Check radiator coolant level when fluid is low in recovery tank. Full Full Diesel Engine stops if fuel level is low. Coolant Recovery Tank Hot Full Capacity: 6 qt (5.7 L) Cold Full Fuel/Coolant_engine1 2012−04 Ref: 907 427−6−2 Fuel NOTICE − Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting (see engine maintenance label for fuel specifications). Leave filler neck empty to allow room for expansion. Coolant Check coolant level in radiator before start- ing unit the first time. If necessary, add coolant to radiator until coolant level is at bottom of filler neck. Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck. Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34°F (−37°C). Add antifreeze to mixture if using the unit in temperatures below −34°F (−37°C). Keep radiator and air intake clean and free of dirt. NOTICE − Incorrect engine temperature can damage engine. Do not run engine without a properly working thermostat and radiator cap. OM-278215 Page 25 Complete Parts List is available at www.MillerWelds.com 5-9. Weld Output Terminals 2 1 Ref: 263 480-A ! Turn off power before connecting to weld output terminals. ! Do not use worn, damaged, undersized, or repaired cables. Negative (−) Weld Output Terminal Positive (+) Weld Output Terminal 1 2 5-10. For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on right and work cable to Negative (−) terminal on left. For Direct Current Electrode Negative (DCEN), reverse cable connections. Use Process/Contactor switch to select type of weld output (see Section 6-3). Connecting To Weld Output Terminals Tools Needed: Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean. 1 6 Stop engine. ! Do not place anything between weld 3/4 in. 3 ! 2 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 4 5 6 Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. 4 5 803 778-B OM-278215 Page 26 Complete Parts List is available at www.MillerWelds.com 5-11. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size. Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft (45 m) 100 ft (30 m) or Less Welding Amperes 10 − 60% Duty Cycle AWG (mm2) 200 ft (60 m) 60 − 100% Duty Cycle 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) 10 − 100% Duty Cycle AWG (mm2) AWG (mm2) 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120) 400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120) 500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95) * This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use ***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding Society at http://www.aws.org. Ref. S-0007-M 2017−08 5-12. Connecting To Remote Receptacle Socket* Socket Information Not all models have contactor control. See description of front panel controls and circuit diagram. 24 VOLTS AC *The remaining sockets are not used. Accessories depend on unit capabilities. REMOTE OUTPUT CONTROL A 24 volts AC. Protected by supplementary protector. B Contact closure to A completes 24 volt AC contactor control circuit. C Output to remote control:+10 volts DC in MIG mode; 0 to +10 volts DC in Stick or TIG mode. D Remote control circuit common. E DC input command signal: 0 to +10 volts from min. to max. of remote control with Voltage/Amperage Adjust control at maximum. F Current feedback: 1 volt per 100 amperes. H Voltage feedback: 1 volt per 10 arc volts. G Circuit common for 24 and 115 volt AC circuit. OR Rmt14_1 2010−04 NEUTRAL OM-278215 Page 27 Complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 7 9 13 10 8 11 14 15 4 6 3 5 1 2 12 277091-A OM-278215 Page 28 Complete Parts List is available at www.MillerWelds.com 6-2. Description Of Front Panel Controls (See Section 6-1) 5 Engine Coolant Temperature Gauge (PipePro Models Only) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions following). Normal temperature is 180 - 203°F (82-95°C). Engine stops if temperature exceeds 230°F (110°C). 2 Weld Controls Engine Control Switch Use switch to start engine, select engine speed, and stop engine. In Run position, engine runs at weld/power speed. In Run/Idle position, engine runs at idle speed at no load and weld speed with load applied. To check engine hours when engine is not running, turn Engine Control switch to Run position. To check remaining oil change hours when engine is not running, turn Engine Control switch to Run/ Idle position. For best performance when welding above 300 amperes, place Engine Control switch in Run position. NOTICE − Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or engine damage. 6 Use receptacle to connect remote controls, wire feeders, and tools requiring 24 VAC. When a remote control is connected to the Remote receptacle, the Auto Remote Sense (ARS) feature automatically switches voltage/amperage control to the remote control (see Section 6-9). With remote control connected, weld output is determined by a combination of front panel and remote control voltage/amperage settings. If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage. If a remote device connected to Remote Receptacle is faulty or is disconnected during operation, the meters display CHEK REMT (see Section 8-12). Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. To Start: NOTICE − Do not use ether or other starting fluids. Using starting fluids voids warranty. If engine does not start, let engine come to a complete stop before attempting restart. Above 325F (05C): turn Engine Control switch to Start. Release Engine Control switch when engine starts. Below 325F (05C): turn engine control switch to Run position. Push Preheat switch up for 6 seconds. Turn Engine Control switch to Start. Release Engine Control switch and Preheat switch when engine starts. Do not operate Preheat switch for more than 20 seconds at a time. To Stop: turn Engine Control switch to Off position. Engine Gauges, Meters, And Lights Remote Control Receptacle 7 Process/Contactor Switch See Section 6-3 for Process/Contactor switch information. 8 Adjust Control/Select Button Adjust Control With Process/Contactor Switch in any SMAW or GTAW process, turn Adjust control to adjust preset amperage. With Process/Contactor switch in any FCAW or GMAW process, turn Adjust control to adjust preset voltage. Select Button Push the control to use as Select button. access Arc Control setting, push and See Section 6-13 for complete fuel, hour, To hold Adjust control for 1 second, then reand engine shutdown information. 3 Fuel Gauge Use gauge to check fuel level. 4 Engine Service Indicator Lights Notifies user that engine oil service is due. Upper LED illuminates when engine oil change hours are between 49−1. Lower LED illuminates when oil change hours are 0 or less. lease. Rotate counterclockwise to set softer arc control. Rotate clockwise to set stiffer arc control. Push Adjust control in and release to save Arc Control setting. Arc Control setting will time out after 5 seconds of inactivity. To access Service Menu, push and hold Adjust control for 5 seconds, then release. See Section 6-4 for Service Menu operation. Service Menu will time out after 5 seconds of inactivity. Weld Meters Weld meters also work in combination to display troubleshooting error codes (see Section 8-12). 9 DC Voltmeter Voltmeter displays preset voltage (GMAW/ FCAW welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections. To set voltage, turn Process/Contactor switch to GMAW or FCAW position. Turn V/A control until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter displays average weld voltage and then defaults to preset voltage. 10 DC Ammeter Ammeter displays preset amperage (Stick and TIG only) when not welding, and actual output amperage when welding. To set amperage, turn Process/Contactor switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on Ammeter. When welding is finished, ammeter displays average weld amperage and then defaults to preset amperage. 11 Arc Control Meter Displays current Arc Control setting. Default value for all processes is 0. Arc Control settings adjust: DIG for SMAW processes, Auto Stop for GTAW processes, and inductance for FCAW and GMAW processes. For softer settings, the LEDs to the left of the star illuminate. For stiffer settings, the LEDs to the right of the star illuminate. No Arc Control settings are accessible for GTAW Remote and CAC-A processes. See Section 6-5. Other Receptacles 12 USB Receptacle Allows software updates from a USB drive (see Section 6-11). A summary file of recoded data from the unit will be saved to a USB drive that is inserted (see Section 6-12). Indicator Lights 13 Setup Light Illuminates when in the Service Menu. 14 In Use Light Illuminates when connected to an ArcReach accessory. 15 Arc Control Light Illuminates when in the Arc Control settings. OM-278215 Page 29 Complete Parts List is available at www.MillerWelds.com 6-3. Process/Contactor Switch 1 1 Process/Contactor Switch ! Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the engine is running. Use switch to select weld process and weld output on/off control (see table below). Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote receptacle. Place switch in Electrode Hot positions for weld output to be on whenever the engine is running. Use the Lift-Arc TIG mode for TIG (GTAW) welding using the Lift-Arc TIG starting procedure (see Section 6-8). Ref. 277091-A REMOTE ON/OFF REQUIRED OUTPUT ON Process/Contactor Switch Setting Typical Process Applications (DC Only) Output On – GMAW/FCAW (MIG) MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not require a control cable back to the welder/generator. Output On – FCAW-S (Electrode Negative) FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that does not require a control cable back to the welder/generator. Output On − SMAW (STICK XX18 and STICK XX10) Stick welding with or without a remote amperage control. Strike an arc to start welding. Output On – GTAW (Lift-Arc TIG) Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the welder/generator to aid arc start. Can be used with or without a remote control. Auto Crater option can be enabled/disabled using the Service Menu (see Section 6-4). Output On – CAC-A (Air Carbon Arc Gouging) Gouging with or without a remote amperage control. Strike an arc to start gouging. Remote ON/OFF Required - GTAW (Remote TIG) High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote control allows remote On/Off and Amperage control. Another typical application is a simple TIG rig with a remote control device. Remote ON/OFF Required - SMAW (Remote Stick) Stick welding with RHC-14 control allows remote On/Off and Amperage control. This can help eliminate accidental arc strikes. Remote ON/OFF Required - GMAW/ FCAW (Remote MIG) MIG solid wire and dual shield flux core using a constant speed feeder. Use feeders with 14-pin remote voltage control, or use a Spoolmatic 30A with WC24 control. OM-278215 Page 30 Complete Parts List is available at www.MillerWelds.com 6-4. Service Menu 1 Adjust Control/Select Button Press and hold control for 5 seconds, then release to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the options and information within each menu item. 1 Rotate the control counterclockwise to decrease the value or select NO/ OFF. Rotate the control clockwise to increase the value or select YES/ ON. Press and release control to save selection. After 5 seconds of inactivity, the menu will time out and the selection will not be saved. Menu Item Selectable Item Option(s) Description HOT STRT LIMT OFF Disables Hot Start option. (Only accessible in SMAW processes) LIMT 1.25 Sets Hot Start current limit, selectable between 1.25 and 2.0 (0.25 increments) in SMAW XX10 and SMAW Remote. LIMT 1.50 Sets Hot Start current limit, selectable between 1.5 and 3.0 (0.5 increments) in SMAW XX18. AUTO CRTR ATCR ON Enables Auto Crater option. (Only accessible in GTAW processes) ATCR OFF Disables Auto Crater option. DIG RNGE 50 - 150 HOUR MTR −− Displays engine hours. OIL HOUR −− Displays remaining oil change hours before service is due. OIL SET 50 HRS Sets the starting hours for oil change period. Selectable from 50−1500 hours in 50 hour increments. OIL RSET RSET YES Resets oil change period to selected value. Unit is set to factory recommended period per engine manufacturer. RSET NO Oil change remaining hours do not reset. VRD ON Enables VRD (Voltage Reducing Device) option, lowering open-circuit voltage. VRD OFF Disables VRD (Voltage Reducing Device) option. SOFT WARE −− Displays the current revision of firmware installed. FACT RSET RSET YES Resets all settings to factory defaults. RSET NO All settings remain at previous settings. VRD Sets current limit above preset amperage between 50 and 150 amps. OM-278215 Page 31 Complete Parts List is available at www.MillerWelds.com 6-5. Arc Control Settings Arc Control is not active when the Process/Contactor switch is in the following positions: Electrode Hot − CAC-A (Air Carbon Arc Gouging) Remote ON/OFF GTAW (Remote TIG) Miller recommends Hobart filler metals. Process/Contactor Switch Arc Control SOFT Starting point for stainless steel wire (high inductance) (−25 to −1) SOFT -12 (0) Starting point for mild steel wire STIFF (1 to 25) Starting point for aluminum wire (low inductance) STIF 12 Voltage sensing feeder SOFT Flat or horizontal welds with XX18 electrode with short weld cables (−25 to −1) (0) Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes STIFF (1 to 25) Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13 electrodes. Also for pipe welding with XX10 and XX18 electrodes STOP (−5 to −1) Auto-Crater off (see Section 6-4). More sensitive Auto-Stop (0) Starting point. STOP (1 to 5) Less sensitive Auto-Stop Lift-Arc start. No Auto Crater allows full control on pipe welds with short or long arc length. Auto Stop feature allows arc to be broken without loss of shielding gas. STOP (−5 to −1) Auto Crater on (see Section 6-4). More sensitive Auto-Crater initiation (0) Starting point STOP (1 to 5) Less sensitive Auto-Crater initiation SOFT (−25 to −1) (0) STIFF (1 to 25) OM-278215 Page 32 Starting point Complete Parts List is available at www.MillerWelds.com Process/Contactor Switch Arc Control SOFT Starting point for stainless steel wire (high inductance) (−25 to −1) SOFT -12 (0) Starting point for mild steel wire STIFF (1 to 25) Starting point for aluminum wire (low inductance). STIF 12 Starting point for dual shield flux core, vertical overhead Wire feeder connects to Remote receptacle STIF 25 6-6. Dynamic Dig Settings Process/Contactor Switch Arc Control SOFT Starting point for 3/32 rod (−25 to −1) SOFT -15 (0) Starting point for XX10 electrode/open root vertical down joint STIFF (1 to 25) Stiffer, more rapidly responding arc Dig Range DIG (50) Starting point for 3/32 rod (100) Starting point for downhill pipe (factory default) DIG RNGE DIG RNGE 65 115 (150) Arc Control SOFT Flat or horizontal welds with XX18 electrode or 3/32 rod with short (−25 to −1) weld cables SOFT (0) -15 Starting point for XX10, XX11, XX13, XX14, XX24, and XX22 electrodes STIFF (1 to 25) Dig Range DIG (50) Starting point for 3/32 rod DIG RNGE 65 DIG RNGE 75 Starting point for XX18 electrode (100) Starting point for downhill pipe (factory default) DIG RNGE 115 (150) OM-278215 Page 33 Complete Parts List is available at www.MillerWelds.com 6-7. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: 1 2 3 1 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 6-8. Lift-Arct TIG With Auto-Stopt And Auto-Cratert Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Arc Start With Lift-Arc 1 Select Lift-Arc at Process/Contactor switch. 2 Turn gas on. 1 2 Touch or scratch. Lift at any angle. Touch tungsten electrode to workpiece at weld start point. Slowly lift electrode. Arc is started when electrode is lifted. Maintain shielding gas coverage and eliminate tungsten and workpiece contamination by using Auto-Crater or Auto-Stop to end the arc. Arc End With Auto-Stop 1 2 3 See Section 6-4 to adjust Auto-Stop and Auto-Crater. Arc End With Auto-Stop: 1 2 3 While welding. Lift torch to start Auto-Stop. Arc stops. Move torch back down to maintain gas coverage and prevent contamination. Arc End With Auto-Crater: OR Remote control is not needed when using Auto-Crater. Arc End With Auto-Crater 1 2 3 4 1 2 3 4 While welding. Lift torch slightly to start Auto-Crater end (current is reduced). Lower torch. Weld current ramps down. Shielding gas continues until shut off. Miller recommends Hobart filler metals. WM Marketing OM-278215 Page 34 Complete Parts List is available at www.MillerWelds.com 6-9. Voltage/Amperage Control With 14-Pin Remote Accessory 1 Remote Receptacle Connect optional remote control to receptacle (see Section 5-12). When a remote control is con- nected to the Remote receptacle, the Auto Remote Sense feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless of the position of the Process/Contactor switch. 1 2 3 2 3 In Example: Min = 20 A DC Max = 205 A DC Voltmeter Shows Open-Circuit Voltage When Not Welding, Arc Voltage While Welding Connect Remote Control To Remote Receptacle 56 205 Turn Remote Control On. Adjust Optional Remote Control to 100% Voltmeter Ammeter Ammeter Shows Preset Output When Not Welding, Actual Amperage While Welding Set V/A Control To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process Voltmeter Toggles Between Preset And Actual Output When Not Welding, Actual Voltage While Welding 28 0 Ammeter Shows Zero Min (20 A DC) Max (205 A DC) Adjust Optional Remote Control to desired weld output Turn Remote Control On. Adjust Optional Remote Control to desired weld output Connect Remote Control To Remote Receptacle Weld meters show preset output when not welding. Set WIRE Process 0774 / Ref.263 482-A / Ref. 263 482-B OM-278215 Page 35 Complete Parts List is available at www.MillerWelds.com 6-10. Operating Engine Block Heater 1 Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Mitsubishi Engine Coolant Heater Specifications Watts Volts ±10% 1000 120 ! NOTICE − In extremely cold weather, heater should be connected to power source when engine is warm. Kubota Engine Coolant Heater Specifications Watts Volts ±10% 400 120 Do not run engine while engine block heater is on. ! The area near the engine block heater gets hot. Disconnect plug to turn off heater. 1 Coolant heater1 2018−01 Notes OM-278215 Page 36 Complete Parts List is available at www.MillerWelds.com 6-11. Updating Software Obtain the latest firmware to be loaded from MillerWelds.com. Copy the desired firmware to an approved USB flash drive (see Section 9-1). With the machine turned off, insert the flash drive into the USB receptacle on the front of the machine. Turn the Engine Control switch to the Run or Run/Idle position. Do not start the engine. When the machine has powered up, if valid files exist on the flash drive, the user is prompted to confirm the start of the download. The Voltmeter/Ammeter display reads: AL? NO. Confirm by rotating the Adjust Control/Select button clockwise to select YES. Then press the Select button. After the update has started, do not power down or remove the flash drive until the update is complete. During the download, the left meter display indicates the active download with ALLC, ALLW, AL C, or AL W. The right meter display indicates the percentage of the download completed with a number from 0 to 100. When the update has completed successfully, the machine restarts. Failures are indicated on the meter display. Correction of failed updates depends on what type of failure occurred. OM-278215 Page 37 Complete Parts List is available at www.MillerWelds.com 6-12. Summary File 1 1 Summary File Each time a USB stick is inserted in the USB receptacle, a summary file is saved to the USB stick as SummaryFile.txt. “USB ACC” will display as the file is written. File is complete when display no longer shows “USB ACC.” The summary file provides diagnostic and weld information. OM-278215 Page 38 Complete Parts List is available at www.MillerWelds.com 6-13. Fuel/Hour Gauge Descriptions OM-278215 Page 39 Complete Parts List is available at www.MillerWelds.com 6-14. Associating ArcReach Devices (ArcReach Models Only) ! Stop engine. NOTICE − Do not exceed machine duty cycle. Associating ArcReach Device To Engine Driven Welder/Generator Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection diagrams. The welder/generator has the ability to associate automatically with an ArcReach device at power up. The Process/Contactor switch must be set to an Output ON mode to associate with an ArcReach device. See the ArcReach device Owner’s Manual to associate the device to the welder/generator. When the association process is complete, the In Use light will be illuminated. Depending on the capabilities of the ArcReach device, the Process/Contactor switch, Adjust Control/Select button, and Arc Control adjustment may be overridden. The following ArcReach accessories are compatible with this welder/generator: ArcReach Stick/TIG Remote ArcReach SuitCase Feeders ArcReach Smart Feeder For Stick Or TIG Welding For MIG Or FCAW Welding For Advanced Wire Processes When welder/generator is associated with Stick/TIG Remote: SMAW processes: Amperage, Electrode Type, and Arc Control settings are adjusted on the remote. GTAW and CAC-A processes: Amperage settings are adjusted on the remote. When welder/generator is associated with Suitcase X-TREME ArcReach feeder, voltage and wire feed settings are adjusted on the feeder. When welder/generator is associated with Smart Feeder, all controls switch to the feeder, and the display reads SMRT ACC. When using an ArcReach device, engine speed weld/power speed. is always 274460-A / 266206-D OM-278215 Page 40 Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 2 1 4 5 3 263 481-A ! ! 1 Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacle to power life support equipment. Unplug power cord before attempting to service accessories or tools. 120 V 20 A AC GFCI Receptacles GFCI1 And GFCI2 ! Test GFCI monthly. See Section 7-2 for GFCI information and for resetting and testing procedures. overload. If CB5 opens, the receptacles do not work. Place CB5 switch in On position to reset circuit breaker. 2 240 V 50 A AC Receptacle RC11 If a supplementary protector continues RC11 supplies 60 Hz single-phase power at weld/power speed. Maximum output from RC11 is 10 kVA/kW. 3 Supplementary Protector CB4 4 Supplementary Protector CB6 5 Supplementary Protector CB5 GFCI1 and GFCI2 supply 60 Hz single-phase power at weld/power speed. See Section 7-2 for GFCI information and for resetting and testing procedures. CB4 protects GFCI2 and CB6 protects GFCI1 from overload. If a supplementary protector opens, the receptacle does not work. Press button to reset. Maximum output from these receptacles is 2.4 kVA/kW. Supplementary protector CB5 protects receptacles and the generator winding from to open, contact Factory Authorized Service Agent. Generator power decreases as weld output increases. Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator. EXAMPLE: If 15 A is drawn from each 120 V receptacle , only 26 A is available at the 240 V receptacle: 2 x (120 V x 15 A) + (240 V x 26 A) = 10.0 kVA/kW OM-278215 Page 41 Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Alternate location for red and green indicator LEDs. 1 2 5 4 3 Orientation of receptacle may be different in other applications. RotGFCI1 2018-01 ! ! 1 2 3 4 5 Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacle to power life support equipment. Unplug power cord before attempting to service accessories or tools. 120 V 20 A AC GFCI Receptacle GFCI Receptacle Test Button GFCI Receptacle Reset Button Red GFCI Indicator Light (LED) Green GFCI Indicator Light (LED) Red and Green indicator lights may be combined in a single LED. GFCI Receptacles GFCI receptacles protect the user from electric shock if a ground fault occurs in equipment connected to the receptacle. A ground fault occurs when electrical current takes the shortest path to ground (which could be through a person) rather than follow its intended safe path. OM-278215 Page 42 If a ground fault is detected, the GFCI Reset button pops out, and the circuit opens to disconnect power to the faulty equipment. A GFCI receptacle does not protect against circuit overloads, short circuits, or shocks not related to ground faults. Reset and test GFCI receptacle according to the following procedures. A solid green LED indicates power to the GFCI. A solid red LED indicates that the GFCI has been tripped. Resetting GFCI Receptacles If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle. Check for damaged or wet tools, cords, plugs, etc. connected to the receptacle. Start engine, place ignition switch in RUN position, and press GFCI Reset button. Reconnect equipment to GFCI receptacle. If GFCI Reset button pops out again, check the equipment and repair or replace if faulty. Resetting/Testing GFCI Receptacle Testing GFCI Receptacles ! Test GFCI monthly. ! Start engine and press the GFCI Test button. The GFCI Reset button should pop out. If Red LED blinks, stop using GFCI receptacle and have it replaced by a Factory Authorized Service Agent. Press the GFCI Reset button. ! Extension cords with bad insulation or of extended length can allow enough leakage current to trip the GFCI circuit. Reset and test as follows. Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur: GFCI does not trip when tested Red LED blinks GFCI does not reset. Complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Mitsubishi Maintenance Label j 239396-K OM-278215 Page 43 Complete Parts List is available at www.MillerWelds.com 8-2. Kubota Maintenance Label j 287 061-F OM-278215 Page 44 Complete Parts List is available at www.MillerWelds.com 8-3. Routine Maintenance ! Recycle engine fluids. = Check = Change = Clean * To be done by Factory Authorized Service Agent Stop engine before maintaining. See Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. = Replace Reference Every 8 Hours Section 5-8, 5-5, 5-6 See engine manual for fuel specifications. Coolant Level Fuel Level See engine manual for oil specifications. Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion. Oil Level Oil, Fuel Spills Every 100 Hours Section 8-4 Battery & Weld Terminals Air Cleaner Hoses Every 250 Hours Kubota Every 500 Hours Mitsubishi NOTICE − Change engine oil and filter after initial 50 to 75 hours of use. Air Cleaner Element Unreadable Labels Engine Manual, Section 8-6, 8-11 1/2 in. (13 mm) Oil Oil Filter Fan Belt Tension Every 500 Hours All Models Spark Arrestor Kubota FUEL Section 5-11, 8-11 SLUDGE Weld Cables Radiator Thermostat Every 1000 Hours Fuel Filter Kubota Sediment Filter Drain Sludge Section 5-8, 8-7, and Engine Manual OR Slip Rings* Brushes* Valve Clearance* Inside Unit Radiator Fluid Level Every 2000 Hours Injectors* Kubota Engine America 505 Schelter Road Lincolnshire, IL 60069 Phone: 847-955-2500 Fax: 847-955-2699 To find a service facility near you, contact the KEA distributor in your area: http://www.kubotaengine.com Mitsubishi Engine North America 1250 Greenbriar Dr., Suite E Addison, IL 60101 630−268−0750 Http://www.mitsubishi−engine.com Use web site to locate closest dealer. For international information, use: http://www.mhi.co.jp/global/network OM-278215 Page 45 Complete Parts List is available at www.MillerWelds.com 8-4. Servicing Air Cleaner ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element. 4 1 2 NOTICE − If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection. Never clean a safety element. Replace the safety element after servicing the primary element three times. 3 Optional 1 2 5 6 7 3 4 8 Intake Manifold Service Indicator (Optional, Customer Supplied) Service Indicator Window Service Indicator Reset Button Service air cleaner element if red band appears in window. A green band means air cleaner is okay. Press button to reset indicator. Clean or replace primary element if dirty (see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six cleanings. Optional 9 5 Housing 6 Safety Element (Optional) 7 Primary Element 8 Cover 9 Dust Ejector To clean air filter Wipe off cover and housing. Remove cover and dump out dust. Remove element(s). Wipe dust from inside cover and housing with damp cloth. Reinstall safety element (if present). Reinstall cover. Keep nozzle 2 in (51 mm) from element. ! Do not clean housing with air hose. Clean primary element with compressed air only. Air pressure must not exceed 100 psi (690 kPa). Use 1/8 in (3 mm) nozzle and keep nozzle at least 2 in (51 mm) from inside of element. Replace primary element if it has holes or damaged gaskets. Blow Inspect Reinstall primary element and cover (dust ejector down). aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B OM-278215 Page 46 Complete Parts List is available at www.MillerWelds.com 8-5. Checking Generator Brush Assembly ! Stop engine and let cool. 1 Generator Brush Assembly Mark and disconnect leads at brushholder assembly. Remove assembly. Press on brush to be sure springs compress. 1 Replace assembly if brushes are damaged. 1 Replace assembly if brushes are damaged or if brush material is at or near minimum length. Check length from brushholder surface. New Length: 5/8 in. (16mm) Minimum Length: 1/4 in. (6.5mm) GenBrush2 2018-01 / Ref 205725 8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe 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 fireproof material. ! 3 Stop engine and let cool. Reinstall cleanout plug. 1 Tools Needed: 3/8 in. 2 803 582 / Ref. 245 609 OM-278215 Page 47 Complete Parts List is available at www.MillerWelds.com 8-7. Servicing Engine Cooling System ! Stop engine and let cool. 1 Radiator Cap Cover 2 Radiator Draincock 3 Coolant Recovery Tank Change coolant according to engine manual. Add coolant according to engine maintenance label. 1 Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator when cold. Add coolant if level is below bottom of radiator filler neck. 2 3 Coolant1 2018−01 / Ref. 907427-6 Notes OM-278215 Page 48 Complete Parts List is available at www.MillerWelds.com 8-8. Mitsubishi Engine Speed Adjustment NOTICE − Engine speed is not adjustable. Attempting engine speed adjustment may affect warranty. 8-9. Kubota Engine Speed Adjustment Engine Speed (No Load) 1890 RPM max (63 Hz) 1500 RPM (50 Hz) 3 4 1 5 Stop 3 Tools Needed: ! 2 2 Low Speed Adjustment Screw Engine speed is factory set and should not require adjustment. After tuning engine, check engine speed with tachometer or frequency meter. See table for proper no load speed. If necessary, adjust speed as follows: 3 4 Lock Nut Throttle Solenoid Rod Start engine and run until warm. Low speed adjustment screw is not used to adjust engine speed when automatic idle option is installed. To prevent solenoid damage, be sure a 1/8 in. (3 mm) gap exists between the engine low speed screw and the Stop engine and let cool. Turn Process/Contactor switch to Stick − Weld Terminals Always On position. 1 High Speed Adjustment Screw Loosen nut. Turn high speed adjustment screw until engine runs at weld/power speed. Tighten nut. throttle lever when the solenoid is held in the energized position. Adjust length of the throttle solenoid rod until engine runs at idle speed. Do not set engine speed higher than specified. 5 Engine Stop Lever Use lever to stop engine. ! Stop engine. Close door. OM-278215 Page 49 Complete Parts List is available at www.MillerWelds.com Notes OM-278215 Page 50 Complete Parts List is available at www.MillerWelds.com 8-10. Overload Protection ! Stop engine. When a circuit breaker, supplementary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely. 2 3 Circuit Breaker CB1 (Not Shown) Supplementary Protector CB2 4 Supplementary Protector CB3 5 Supplementary Protector CB8 6 Circuit Breaker CB9 (Kubota Engine Models) CB1 protects the engine battery circuit. If CB1 opens, the engine will not crank. CB1 automatically resets when the fault is corrected. CB2 protects the engine wiring harness. If CB2 opens, the engine will not crank. CB3 protects part of the weld control wiring harness. If CB3 opens, weld and generator power output stops. 1 3 CB8 protects the 24 volt AC output to remote receptacle RC14. If CB8 opens, 24 volt output to RC14 stops. Press button to reset supplementary protector. 6 CB9 protects the throttle solenoid against overload. If CB9 opens, the engine does not automatically idle down. Check the linkage and solenoid. CB9 automatically resets. 4 5 OM-278215 Page 51 Complete Parts List is available at www.MillerWelds.com 8-11. Servicing Fuel And Lubrication Systems ! 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 2 3 4 5 6 7 Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter Secondary Fuel Filter Fuel Tank Sludge Drain Valve Fuel Filter Clamps To change oil and filter: Route oil drain hose and valve through hole in base. See engine manual and engine maintenance label for oil/filter change information. See Section 6-4 to reset the oil change hours following service. 6 2 Tools Needed: 803 563 / Ref 214 777−E OM-278215 Page 52 Complete Parts List is available at www.MillerWelds.com To replace primary fuel filter: For Kubota Engines: Turn filter counterclockwise. Remove filter. For Mitsubishi Engines: Turn filter retaining ring counterclockwise to remove. Pull filter straight down to remove. Kubota Engine 3 Fill new filter with fresh fuel. Apply thin coat of fuel to gasket on new filter. 4 For Kubota Engines: Install new filter and turn clockwise. For Mitsubishi Engines: Install new filter and reinstall retaining ring. 7 Bleed air from fuel system according to engine manual. 5 Inspect fuel lines, and replace if cracked or worn. To drain water from fuel system: 7 See engine manual. To replace secondary fuel filter: Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter, reconnect fuel lines, and reinstall clamps. To drain sludge from fuel tank: 1 ! Beware of fire. Do not smoke and keep sparks and flames away from drained fuel. Dispose of drained fuel in an environmentally safe manner. Do not leave unit unattended while draining fuel tank. ! Properly lift unit and secure in a level position. Use adequate blocks or stands to support unit while draining fuel tank. Mitsubishi Engine 4 3 Attach 1/2 ID hose to drain valve. Put metal container under drain, and use screwdriver to open sludge drain valve. Close valve when sludge has drained. Remove hose. 7 Close door. 5 7 1 7 OM-278215 Page 53 Complete Parts List is available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Error Displays IGBT Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. TEMP Display Example When an error is displayed, normally weld output has stopped but generator power output may be okay. To reset error displays, stop unit and then restart. See below to reset CHEK REMT display. Error Display Description CHEK REMT Indicates a remote device connected to the Remote Receptacle may be faulty. CHEK REMT is also displayed whenever a remote device has been connected to the Remote Receptacle and then disconnected. Clear fault by stopping and restarting the unit, or by turning Process/Contactor switch to another position. If problem continues, have Factory Authorized Service agent check the remote device and main control board PC1. IGBT 1SHT Indicates the thermistor in IGBT module 1 has shorted. Have Factory Authorized Service Agent check unit. IGBT 1OPN Indicates the thermistor in IGBT module 1 is open. Have Factory Authorized Service Agent check unit. IGBT 2SHT Indicates the thermistor in IGBT module 2 has shorted. Have Factory Authorized Service Agent check unit. IGBT 2OPN Indicates the thermistor in IGBT module 2 is open. Have Factory Authorized Service Agent check unit. IGBT TEMP Indicates an IGBT module has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle. Keep engine access door closed when running unit to maintain proper cooling airflow past module. Allow unit to cool before restarting. If problem continues, have Factory Authorized Service Agent check unit. MAX POWR Engine power limit exceeded, causing weld output to be temporarily reduced. Error clears after 5 seconds. S/W ERR Software version mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service Agent check unit. S/W BLD Software build mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service Agent check unit. 8-13. Maintaining Stainless Steel (Models With Optional Package) Stainless steel is very resistant to rust and corrosion; however, it must be kept clean to ensure rust and corrosion resistance. Units used in corrosive environments (chlorine or salt water environment for example) should be cleaned with mild soap and water frequently. If dirt buildup occurs, use a stainless steel cleaner to remove buildup. With proper maintenance, stainless steel maintains its luster and appearance. 8-14. Battery Maintenance Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open-circuit voltage drops to 12.4 volts DC when measured across the battery terminals. OM-278215 Page 54 Complete Parts List is available at www.MillerWelds.com 8-15. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12). A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at AC receptacles. On/Off Switch Required position and turn remote contactor on (see Section 5-12). Reset supplementary protector CB8 (see Section 8-10). Check for faulty remote device connected to Remote receptacle. Check and secure connections to Remote receptacle (see Section 5-12). Check Voltmeter/Ammeter error displays (see Section 8-12). No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up. put at AC receptacles. Reset supplementary protector CB3. (see Section 8-10). Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service Agent check PC1. Check Voltmeter/Ammeter error displays (see Section 8-12). Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit. Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and tight. Use dry, properly stored electrodes. Remove excessive coils from weld cables. Have Factory Authorized Service Agent check brushes and slip rings. High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1. Low weld output. Check engine speed, and adjust if necessary. Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service Agent check the rotor. Low open-circuit voltage. Check engine speed, and adjust if necessary. Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main rectifier. No remote fine amperage control. Repair or replace remote control device. Check and secure connections to Remote receptacle (see Section 5-12). No 24 volt AC output at Remote Reset supplementary protector CB8 (24 volt) (see Section 8-10). receptacle. B. Generator Power Trouble Remedy No generator power output at AC recept- Reset receptacle supplementary protector(s) (see Section 7-1). Check and reset GFCI receptacle if neacles; weld output okay. cessary (see Section 7-2). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check field excitation circuit. Reset supplementary protector CB3 (see Section 8-10). Check Voltmeter/Ammeter error displays (see Section 8-12). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output at generator power AC Have Factory Authorized Service Agent check field excitation circuit. receptacles. OM-278215 Page 55 Complete Parts List is available at www.MillerWelds.com Trouble Remedy Low output at generator power AC Check engine speed, and adjust if necessary. receptacles. Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service Agent check the rotor. C. Engine Trouble Engine will not crank. Remedy Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-10). Have Factory Authorized Service Agent check engine wiring harness and components. Reset supplementary protector CB2 (see Section 8-10). Check engine wiring harness plug connections. Check Voltmeter/Ammeter error displays (see Section 8-12). Have Factory Authorized Service Agent check Engine Control switch S1 and control relay CR2. Engine cranks but does not start. Check fuel level. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel pump. Air in fuel system. See engine manual. Engine hard to start in cold weather. Use Preheat switch (see Section 6-1). Keep battery in good condition. Store battery in warm area off cold surface. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 8-3). Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow plug. Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Section 5-7 ). Check Voltmeter/Ammeter error displays (see Section 8-12). Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-10). Reset supplementary protector CB2 (see Section 8-10). Have Factory Authorized Service Agent check engine alternator, engine harness, throttle solenoid TS1, fuel solenoid FS1, and the fuel pump. Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, fuel solenoid FS1, and the fuel pump. See engine manual. Engine slowly stopped and cannot be restarted. Check fuel level. Check Voltmeter/Ammeter error displays (see Section 8-12). Check engine air and fuel filters (see Sections 8-4 and 8-11). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to weld speed. Have Factory Authorized Service Agent check current transformer CT1. Engine does not run at idle speed. Have Factory Authorized Service Agent check control relay CR4. Check Voltmeter/Ammeter error displays (see Section 8-12). Check Voltmeter/Ammeter error displays (see Section 8-12). Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11). wetstacking occurs. OM-278215 Page 56 Complete Parts List is available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity . . . . . . . . . . . . . . . . . . . . 276418 . . USB Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1 . . . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244290 . . Brushholder Assembly, Generator w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218468 . . Belt, Alternator (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233482 . . Kit, Fuel Sedimenter (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253901 . . Kit, Filter (Kubota) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196428 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207715 . . . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242883 . . Belt, Alternator (Mitsubishi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252782 . . Filter Kit, Mitsubishi (S4l2) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252781 . . . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213858 . . . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242882 . . . . Filter, Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦197679 . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, 12v 570 Crk 100 Rsv Gp 35 M.F. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ♦Optional To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-278215 Page 57 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator With Kubota Engine OM-264359 Page 58 276789-C OM-264359 Page 59 Figure 10-2. Circuit Diagram For Welder/Generator With Mitsubishi Engine OM-264359 Page 60 278214-B OM-264359 Page 61 SECTION 11 − RUN-IN PROCEDURE run_in1 2014−09 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary. 11-1. Wetstacking 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 Welder/Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current. 2 NOTICE − Do not idle engine longer than necessary. Piston rings only seat correctly if engine runs at weld/ power rpm, and the welder/generator is kept loaded during run-in. 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm. 1 If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures. See the engine manual for additional engine run-in information. OM-278215 Page 62 11-2. Run-In Procedure Using Load Bank Or Resistance Grid 2 1 7 4 3 5 + 6 S-0683 / 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 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. 2 Welder/Generator Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables 4 Resistance Grid Use grid sized for generator rated output. Turn Off grid. 5 Voltmeter 6 Clamp-On Ammeter Connect voltmeter and ammeter as shown, if not provided on generator. Start engine and run for several minutes. For Load Bank Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator (see nameplate, rating label, or the specifications section in this manual). For Resistance Grid Set grid switches and then adjust generator A/V control so load equals rated voltage and current of the generator (see nameplate, rating label, or the specifications section in this manual). Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. NOTICE − Check oil level frequently during run-in; add oil if needed. It is recommended to run the welder/generator for two hours minimum and up to four hours under load. Place A/V control in minimum position, then shut down load bank or grid to remove load. Run engine several minutes at no load. ! Stop engine and let cool. 7 Engine Exhaust Pipe Repeat procedure if wetstacking is present. OM-278215 Page 63 SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 2 1 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has double insulated symbol and/or wording on it. ! 2 Do not use 2-prong plug unless equipment is double insulated. 3 OR gen_pwr 2017−01 − ST-800 577 12-2. Grounding Generator To Truck Or Trailer Frame 1 2 GND/PE 3 800 652-D ! ! 1 2 Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) OM-278215 Page 64 3 Metal Vehicle Frame frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire. Electrically bond generator frame to vehicle frame by metal-to-metal contact. ! Bed liners, shipping skids, and some running gear insulate the welder/generator from the vehicle ! Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. 12-3. Grounding When Supplying Building Systems 1 2 1 Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. 2 3 GND/PE Ground Device Use ground device as stated in electrical codes. 2 3 ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ST-800 576-B 12-4. How Much Power Does Equipment Require? 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 2 3 2 1 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 12-8). VOLTS 115 AMPS 4.5 Hz 50/60 3 Rating Data Rating shows volts and amperes, or watts required to run equipment. Amperes x Volts = Watts Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 3 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts. Example 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (3 x 200W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts. S-0623 OM-278215 Page 65 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty Rating Starting Watts Running Watts 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10,550 15,900 23,300 8100 23,300 35,000 46,700 1000 1400 1850 2400 3500 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10,700 400 550 650 800 1100 12-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) Farm Duty Motors Std. (e.g. Conveyors, Feed Augers, Air Compressors) Farm Duty Motors High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump OM-278215 Page 66 Rating Starting Watts Running Watts 2 HP 1/3 HP 1000 1650 3400 4400 2900 10,500 1720 1000 650 1000 1400 1100 2800 720 1/2 HP 2575 975 3/4 HP 4500 1400 1/4 HP 1/2 HP 3/4 HP 1 HP 6100 1600 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 8200 10,550 15,900 23,300 8100 2200 2850 3900 6800 2000 6000 5 HP 23,300 7-1/2 HP 35,000 8000 10 HP 46,700 10,700 1/2 HP 500 PSI 550 PSI 700 PSI 3300 3150 4500 6100 3100 2150 3100 2100 3200 1000 950 1400 1600 800 750 1000 800 1050 1/3 HP 1/2 HP 1/3 HP 1/2 HP 12-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac Rating Starting Watts Running Watts 1/4 in. 3/8 in. 1/2 in. 6-1/2 in. 7-1/4 in. 8-1/4 in. 9 in. 10 in. 14 in. 6 in. 8 in. 10 in. 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in. 2 HP, 14 in. Standard 9 in. Heavy Duty 12 in. 1/3 HP 18 in. HID Metal Halide Mercury Sodium Vapor 400 GPH 900 GPH 3/4 HP, 16 in. 1 HP, 20 in. 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10,500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250 1000 200 500 1400 1600 950 1400 1600 700 900 1300 OM-278215 Page 67 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 2 Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welder/generator amperage output must be at least twice the motor’s running amperage. (kVA/HP x HP x 1000) / Volts = Starting Amperage Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230, HP = 1/4, kVA/HP = 11.2 (11.2 x 1/4 x 1000) / 230 = 12.2A Starting the motor requires 12.2 amperes. S-0624 12-9. How Much Power Can Generator Supply? 1 Limit Load To 90% Of Generator Output Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 2 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply. Ref. ST-800 396-A / S-0625 OM-278215 Page 68 12-10. Typical Connections To Supply Standby Power 1 2 Utility Electrical Service Transfer Switch Fused Disconnect Switch (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. Customer-supplied equipment 4 3 ! Welding Generator Output is required if generator will supply standby power during emergencies or power outages. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) 5 Essential Loads Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored. Install correct switch (customersupplied). Switch rating must be same as or greater than the branch overcurrent protection. 3 Fused Disconnect Switch Install correct switch (customersupplied) if required by electrical code. 4 Welder/Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring. Connect generator with temporary or permanent wiring suitable for the installation. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. − See Section 12-4). OM-278215 Page 69 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)* Current (Amperes) Load (Watts) 5 600 7 840 10 1200 15 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5) 350 (106) 225 (68) 137 (42) 100 (30) 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15) 37 (11) 35 4200 125 (38) 75 (23) 50 (15) 40 4800 112 (34) 62 (19) 37 (11) 45 5400 100 (30) 62 (19) 50 6000 87 (26) 50 (15) *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)* Current (Amperes) Load (Watts) 5 1200 7 1680 10 2400 15 4 (25) 8 (10) 10 (6) 12 (4) 14 (2.5) 700 (213) 450 (137) 225 (84) 200 (61) 800 (244) 500 (152) 300 (91) 200 (61) 125 (38) 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31) 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18) 20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18) 25 6000 350 (107) 225 (69) 125 (38) 75 (23) 30 7000 300 (91) 175 (53) 100 (31) 75 (23) 35 8400 250 (76) 150 (46) 100 (31) 40 9600 225 (69) 125 (38) 75 (23) 45 10,800 200 (61) 125 (38) 50 12,000 175 (53) 100 (31) *Conductor size is based on maximum 2% voltage drop OM-278215 Page 70 6 (16) Effective January 1, 2018 (Equipment with a serial number preface of MJ or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You 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 expertise of the distributor and Miller is there to help you, every step of the way. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to its original * Batteries retail purchaser that new Miller equipment sold after the effective date of 6. 90 Days — Parts this limited warranty is free of defects in material and workmanship at * Accessory (Kits) the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN * Canvas Covers LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, * Induction Heating Coils and Blankets, Cables, and INCLUDING THE WARRANTIES OF MERCHANTABILITY AND Non-Electronic Controls FITNESS. * M-Guns Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material * MIG Guns, Subarc (SAW) Torches, and External or workmanship. Miller must be notified in writing within thirty (30) days Cladding Heads of such defect or failure, at which time Miller will provide instructions on * Remote Controls and RFCS-RJ45 the warranty claim procedures to be followed. If notification is submitted * Replacement Parts (No labor) as an online warranty claim, the claim must include a detailed * Spoolmate Spoolguns description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 2. 3. 4. 5 Years Parts — 3 Years Labor * Original Main Power Rectifiers Only to Include SCRs, Diodes, and Discrete Rectifier Modules 3 Years — Parts and Labor * Auto-Darkening Helmet Lenses (Except Classic Series) (No Labor) * Engine Driven Welder/Generators (NOTE: Engines are Warranted Separately by the Engine Manufacturer.) * Inverter Power Sources * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources 2 Years — Parts and Labor * Auto-Darkening Helmet Lenses − Classic Series Only (No Labor) * Auto-Darkening Weld Masks (No Labor) * Fume Extractors − Capture 5, Filtair 400 and Industrial Collector Series 1 Year — Parts and Labor Unless Specified * AugmentedArc and LiveArc Welding Systems * Automatic Motion Devices * Bernard BTB Air-Cooled MIG Guns (No Labor) * CoolBelt and CoolBand Blower Unit (No Labor) * Desiccant Air Dryer System * External Monitoring Equipment and Sensors * Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) * RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors − Filtair 130, MWX and SWX Series * HF Units * ICE/XT Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers (NOTE: Digital Recorders are Warranted Separately by the Manufacturer.) * Load Banks * Motor-Driven Guns (except Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks * Running Gear/Trailers * Spot Welders * Subarc Wire Drive Assemblies * TIG Torches (No Labor) * Tregaskiss Guns (No Labor) * Water Cooling Systems * Wireless Remote Foot/Hand Controls and Receivers * Work Stations/Weld Tables (No Labor) Miller’s True Blue® Limited Warranty shall not apply to: 1. 2. 3. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.) Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. The exclusive remedies for warranty claims are, at Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Miller, (3) the pre-approved cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon use). Products may not be returned without Miller’s written approval. Return shipment shall be at customer’s risk and expense. The above remedies are F.O.B. Appleton, WI, or Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER. Some US states do not allow limiting the duration of an implied warranty or the exclusion of certain damages, so the above limitations may not apply to you. This warranty provides specific legal rights, and other rights may be available depending on your state. In Canada, some provinces provide additional warranties or remedies, and to the extent the law prohibits their waiver, the limitations set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary by province. miller_warr 2018-01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. LLC An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams For International Locations Visit www.MillerWelds.com Welding Process Handbooks To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 © 2018 Miller Electric Mfg. LLC 2018−01
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