Miller BIG BLUE 400X PRO CE CAT/KUBOTA User manual

Miller BIG BLUE 400X PRO CE CAT/KUBOTA User manual
OM-281496H
2019-10
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 X Pro
®
CAT, Kubota
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
OWNER’S MANUAL
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.
From Miller t
Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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, and our extensive service network is there to help fix the problem.
Warranty and maintenance information for your particular model are
also provided.
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 2019-01
Miller is the first welding
equipment manufacturer in the
U. S. A. to be registered to the
ISO 9001 Quality System
Standard.
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
BIG BLUE 500 X PRO (PERKINS) CE W/ ARCREACH
BIG BLUE 400 X PRO (KUBOTA) CE
BIG BLUE 400 X PRO (KUBOTA) CE W/ ARCREACH
BIG BLUE 400 X PRO (CAT) CE
Stock Number
907761
907732010
907732011
907758
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory
Effects
10 cm
0.16
Health
Effects
10 cm
0.11
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.18
3 cm
0.10
3 cm
0.23
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
8 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
282267-A
Tony Samimi
Date tested:
2016-02-22
182 cm
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3
Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4
Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5
Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-7
Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1
Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3
Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4
Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-5
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-6
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-7
Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-8
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-1
Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-2
Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1
Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2
Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-3
Weld, Power, And Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-4
Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-5
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-6
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-7
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-8
AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-9
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1
Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2
Grounding Generator to Truck or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3
Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-4
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5
Kubota Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6
CAT Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-7
Engine General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-8
Engine Fuel And Coolant Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-9
Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-10 Connecting Weld Output Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-11 Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-12 Connecting To Remote Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1
Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2
Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-3
Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-4
Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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
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
Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
CAT 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
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9
Maintaining Stainless Steel (Models With Optional Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 CAT Engine Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11 CAT Turbo Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12 Kubota Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14 Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15 Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-16 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
35
35
36
37
38
39
40
41
42
43
43
44
45
45
46
47
48
49
49
50
50
50
51
51
52
53
54
56
57
59
59
60
66
66
67
68
77
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
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.
1-2.
� 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.
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.
� Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed.
� 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.
� Wear dry, hole-free insulating gloves and body protection.
� Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
� 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 touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
� Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
� Wear a safety harness if working above floor level.
� Use AC output ONLY if required for the welding process.
� Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
� If AC output is required, use remote output control if present on
unit.
� 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!
� Keep all panels and covers securely in place.
� 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.
SIGNIFICANT DC VOLTAGE exists in inverter power sources
AFTER stopping engine.
� Stop engine on inverter and discharge input capacitors according
to instructions in Manual before touching any parts.
OM-281496 Page 1
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.
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 GASES can be
hazardous.
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.
OM-281496 Page 2
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.
� 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.
� 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.
� Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
� Keep protective cap in place over valve except when cylinder is in
use or connected for use.
� Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
� Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
� 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.
1-3.
� Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
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.
EXHAUST SPARKS can injure.
� 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.
� 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.
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.
� Stop engine before installing or connecting unit.
� Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
BATTERY ACID can BURN SKIN and
EYES.
� To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
� Do not tip battery.
� Keep hands, hair, loose clothing, and tools away from moving
parts.
� Flush eyes and skin immediately with water.
� Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine.
� Replace damaged battery.
ENGINE HEAT can cause fire.
� Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
� Do not locate unit on, over, or near combustible
surfaces or flammables.
� Block flywheel so that it will not turn while working on generator
components.
� Keep exhaust and exhaust pipes way from
flammables.
OM-281496 Page 3
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.
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.
1-5.
� 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.
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.
OM-281496 Page 4
� Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94-110) when manually
lifting heavy parts or equipment.
OVERHEATING can damage motors.
HIGH PRESSURE FLUIDS can injure
or kill.
� Engine fuel system components can be under high
pressure.
� Turn off or unplug equipment before starting or
stopping engine.
� Before working on fuel system, turn off engine to
release pressure.
� Do not let low voltage and frequency caused by
low engine speed damage electric motors.
� If any fluid is injected into the skin or body seek medical help
immediately.
� Use only equipment suitable for operation on 60 or 50/60 Hz
power.
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.
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.
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.
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.
� Reduce current or reduce duty cycle before starting to weld again.
� Do not block or filter airflow to unit.
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.
TILTING OF TRAILER can injure.
� Do not allow tools to cause sparks when working on a battery.
� Use tongue jack or blocks to support weight.
� Do not use welder to charge batteries or jump start vehicles unless
it has a battery charging feature designed for this purpose.
� Properly install welding generator onto trailer according to instructions supplied with trailer.
� 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.
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.
� Do not charge batteries in a closed area or where ventilation is
restricted.
� Have only qualified persons familiar with electronic equipment perform this installation.
� Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
� The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
� Before charging battery, select correct charger voltage to match
battery voltage.
� If notified by the FCC about interference, stop using the equipment
at once.
� Set battery charging controls to the Off position before connecting
to battery. Do not allow battery charging clips to touch each other.
� Have the installation regularly checked and maintained.
� Keep charging cables away from vehicle hood, door, or moving
parts.
� 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.
OM-281496 Page 5
ARC WELDING can cause
interference.
� 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.
1-6.
� 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.
California Proposition 65 Warnings
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.
For Diesel Engines:
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 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: 212-6424900, website: www.ansi.org).
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).
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).
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 P1, 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).
1-8.
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 312353-2220, 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).
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-281496 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
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.
Symboles utilisés
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.
2-2.
� 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 cidessous y afférant pour les actions nécessaires afin d’éviter le
danger.
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 ciaprès 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.
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!
� Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.
� 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.
� 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.
� Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
� 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
� Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide
doublée.
OM-281496 Page 7
� N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp 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.
� 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.
OM-281496 Page 8
� 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.
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 couper ou souder des jantes ou des roues. Les pneus peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées
peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les
normes de sécurité.
� 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.
� Porter des protections approuvés pour les oreilles
si le niveau sonore est trop élevé.
2-3.
Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants
médicaux.
� 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.
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.
� 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.
� 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.
� 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.
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.
OM-281496 Page 9
� 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, panneaux, recouvrements et dispositifs de protection.
� 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.
� 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.
2-4.
� 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
précisé 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.
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.
OM-281496 Page 10
� 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.
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.
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.
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.
�
�
� 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.
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.
2-5.
� 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.
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.
OM-281496 Page 11
� 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.
� Utiliser uniquement des équipements adéquats pour un fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
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.
� 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.
OM-281496 Page 12
� 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.
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.
2-6.
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.
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 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: 212-6424900, website: www.ansi.org).
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).
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.)
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 P1, 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).
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).
OM-281496 Page 13
Manuel de service de batterie, Battery Council International, 330
North Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone : 1312-245-1074, site Web : www.batterycouncil.org).
2-8.
ROM-FR 2018–06
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.
OM-281496 Page 14
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.
Safe
Safe8
Safe8
Parts List is available at www.MillerWelds.com
� Complete
1-1. Additional
Safety
Symbols And Definitions
Connectgreen
green or
or green/yellow
green/yellow grounding
grounding conductor
conductor to
to groun
groun
Connect
Connect
terminal.green or green/yellow grounding conductor to ground
terminal.
terminal.
SECTION
3 – DEFINITIONS
Connect input
input conductors
conductors (L1,
(L1, L2
L2 And
And L3)
L3) to
to line
line terminals.
terminals.
Connect
are found only on CE products.
Some symbols
Connect input conductors (L1, L2 And L3) to line terminals.
3-1.
Safe
Safe8
Safe8
Additional Safety Symbol Definitions
� Some symbols are found only on CE products.
Never use
use generator
generator inside
inside aa home
home or
or garage,
garage, even
even ifif doors
doors a
Never
Never
use
generator
inside a home or garage, even if doors a
Warning! Watch Out! There are possible hazards as
shown
the symbols.
dows
areby
open.
dows
are
open.
dows
open. hazards as shown by the
Warning! Watch Out! There
areare
possible
Safe8
Safe87
symbols.
Safe
Safe87
Do not discard product (where
with
general
waste.
Do notapplicable)
discard
product
(where
applicable)
with after
general
waste.
Hazardous
voltage
remains
onuse
input
capacitors
power
turned
Only
use
generator
outside
and far
faris
away
from windows,
windows, doo
doo
Only
generator
outside
and
away
from
Hazardous
voltageWaste
remains
on use
input
capacitors
afterEquipment
power
is
turned
Reuse
or recycle
Electrical
and
Electronic
(WEEE)
Only
generator
outside
and
away
from windows,
door
off.
Do not
touch
fully charged
capacitors.
Always
wait
60far
seconds
Reuse or recycle Wasteoff.
Electrical
and
Electronic
Equipment
(WEEE)
by
disposing
at
a
designated
collection
vents.
vents.
Do
not touch
fully
charged
capacitors.
Always
wait
60
seconds
by
disposing
at
a
designated
collection
facility.
vents. working on unit, AND check input caafter power is turned off before
facility.
after
power
is turned
off before working
on unit,
check input
caContact
your
local
or 0
your
localAND
distributor
further
pacitor
voltage,
andrecycling
be sure itoffice
is near
before
touching
anyfor
parts.
pacitor
voltage,
and
be
sure
it is near
beforeinformation.
touching any parts.
Contact your local recycling
office
or
your
local
distributor
for0further
Safe8
information.
Safe88
Safe3
Safe88
Safe42 2017 04
Safe42 2017 04
Do not usevoltage
ether orremains
other starting
fluids.
Using starting
fluids
voids
Hazardous
oninput
input
capacitors
afterpower
power
is
turned
Hazardous
voltage
remains
on
capacitors
after
turned
Do not
not use
use ether
ether or
or other
other
startingSee
fluids.
Using
starting
fluids
voids warranty.
warranty.
Seeis
engine
Owner’s Manual.
Manual.
Do
starting
fluids.
Using
starting
fluids
voids
See
engine
Owner’s
warranty.
engine
Owner's
Manual.
off.
Do
not
touch
fully
charged
capacitors.
Always
wait
5
minutes
after
Do not use ether or other
starting
fluids.
Using
starting
fluids
voids
warranty.
See
engine
Owner’s
Manual.
off. Do
not
touch
fully
charged
capacitors.
Always
wait
5 minutes
after
Wear dry insulating gloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
power
is
turned
off
before
working
on
unit,
AND
check
input
capacitor
power is turned off before working on unit, AND check input capacitor
Safe
Safe
voltage, and
andbe
besure
sureititisisnear
near00before
beforetouching
touchingany
anyparts.
parts.
voltage,
Safe8
Safe43
2017
Safe43
2017
04 04
==<< 60°
60°
Always
liftand
and
support
unit
using
both
handles.
Keep
angleofof
lifting
Always
lift
support
unit
using
both
handles.
Keep
angle
lifting
Hot
muffler
and
exhaust
pipe
can
cause
severe
burns.
Hot muffler
muffler and
and exhaust
exhaust
pipe
can
cause
severe
burns.
Hot
pipe
can
cause
severe
burns.
device
lesscause
than60
60
degrees.
less
than
degrees.
Hot muffler and exhaustdevice
pipe can
severe
burns.
Use aashock
properby
cart
tomove
moveyourself
unit. from work and ground.
Use
proper
cart
to
unit.
Protect yourself from electric
insulating
Safe
Safe
Safe
Safe9
Safe44
2012
Safe44
2012
05 05
Safe
Keep your head out of the fumes
Welding,
cutting,
drilling,
grinding
onexplosion.
base can cause fire or
Welding,cutting,
cutting, drilling,
drilling,
or grinding
grinding
on base
base
canor
cause
fire or
or
explosion.
Welding,
or
on
can
cause
fire
Welding, cutting, drilling,Engine
or grinding
on base
can
orcause
explosion.
fuel
flames
ororcause
sparks
can
fire.
Engine
fuelplus
plus
flames
sparksfire
can
cause
fire.
explosion.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe7 2017 04
Safe45
2012
05 05
Safe45
2012
Become trained and read the instructions before working on the
machine or welding.
Remove
crate.
Remove
Owner’s
Manual
from
unit.
Remove
unit
from
shipping
crate.
Remove
Owner’s
Manual
from
unit.
Removeunit
unitfrom
fromshipping
shipping
crate.
Remove
Owner's
Manual
from
unit.
Do not
not spray
spray water
water on
onFollow
CST
units.
instructions
install
muffler.
Do
CST
units.
Follow
instructions
install
muffler.
Follow
instructionstototo
install
muffler.
Do not spray water on CST
units.
Safe40 2012 05
Disconnect input plug or power before working on machine.
Safe46
2012
05 05
Safe46
2012
Become trained and read the instructions before working on the
machine or cutting.
Read
Read Owner’s
Owner’sManual.
Manual.Read
Readlabels
labelson
onunit.
unit.
Read Owner's Manual. Read labels on unit.
Door must
must be
be fully
fully open
open during
during operation.
operation.
Door
Door
be fully
during
operation.
Keepmust
your head
outopen
of the
fumes.
/
+
Safe
Safe
Safe
Safe9
Safe
Safe41 2012 05
Safe47 2012 05
Safe47 2012 05
Safe
Safe
Safe9
Safe
Safe
Safe9
Remove
unit from
Remove
from unit.
Safe
Move jumper
links shipping
as showncrate.
on inside
labelOwner’s
to matchManual
input voltage
at
Move
jumper
links
as
shown
on
inside
label
to
match
input
voltage
at
Follow
instructions
to
install
muffler.
<12.4 V
job site. Include extra length in grounding conductor and connect
job site. Include
extrafirst.
length
in grounding
conductor
and
grounding
conductor
Connect
input
conductors
asconnect
shown on
Read Owner’s
Manual
for
batteryline
maintenance
information.
grounding
conductor
first.
Connect
input
conductors
as
shown
on
Drive rolls
rolls can
can injure
injure fingers.
fingers.
Welding
wire and
and
drive
partsline
are at
at welding
welding
voltage
during
operation
keep han
han
Drive
Welding
wire
drive
parts
are
voltage
during
operation
keep
inside
label.
Double-check
all
connections,
jumper
link
positions,
and
Safe46
2012
05
Drive
rolls
can
injure
fingers.
Welding
wire
and
drive
parts
are
at
welding
voltage
during
operation
keep hand
inside
label.
Double-check
all
connections,
jumper
link
positions,
and
and metal
metal objects
objects away.
away.
and
input voltage before applying power.
Keepmetal
your objects
head out
of the
fumes
and
away.
input voltage before applying power.
Safe49 2012 05
Read Owner's Manual for battery maintenance information.
Safe49 2012 05
Every 100 hours, check and clean filter and check condition of hoses.
+
Safe117 2014 06
Plugged filter or hoses can cause overheating to the power source
Plugged
source
and
torch.filter or hoses can cause overheating to the power
Safe51
2012
and torch.
Use forced ventilation or local exhaust to remove the fumes.
05
Safe50 2012 05
Safe50
2012
During
the
first
ofofoperation
above
200
During
theControl
first50
50hours
hours
operationkeep
keepwelding
weldingload
load
above
200 05
Do not spray water on electrical parts, including
Engine
Unit
(ECU).
amperes.
amperes.Do
Donot
notweld
weldbelow
below200
200amperes
amperesofofoutput.
output.
Every 100 hours, check and clean filter and check conditionSafe
of hoses.
118 2014
Safe54
04
Every 100 hours, check and clean filter and check condition
of 2017
hoses.
Use forced ventilation or local exhaust to remove the fumes.
Recycle or dispose of used coolant in an environmentally safe way.
Safe
10
Safe51 2012 05
Safe51 2012 05
After the first 50 hours of operation, change the engine oil and filter.
Use coolant suggested by the manufacturer.
Use coolant suggested by the manufacturer.
Safe
Safe
Safe9
Safe
Safe119 2015 05
OM-281496 Page 15
Safe55 2012 05
Safe52 2012 05
Safe
amperes. Do not weld below 200 amperes of output.
Become trained and read the instructions before working on the
Become
trained and read the instructions before working on the
at www.MillerWelds.com
� Complete Parts List is available
machine
heating.
machine
ororheating.
Safe54 2017 04
Safe85 2012 06
Safe85 2012 06
After the first 50 hours of operation, change the engine oil and filter.
After the first 50 hours of operation, change the engine oil and filter.
Connect
greenororgreen/yellow
green/yellowgrounding
groundingconductor
conductortotoground
ground
Connect
green
terminal.
terminal.
Safe55 2012
Connectinput
inputconductors
conductors(L1,
(L1,L2L2And
AndL3)
L3)totoline
lineterminals.
terminals.
Connect
05
Safe86 2012 06
Safe86 2012 06
Never
use
generator
inside
aahome
or
garage,
even
and
winNever
use
generator
inside
a
home
garage,
even
ifdoors
doors
and
winNever
use
generator
inside
home
oror
garage,
even
ifif doors
and
winWear dry insulating gloves. Do not touch electrode
(wire)
with
bare hand.
Do
not wear
wet or damaged
gloves.
dows
areare
open.
dows
are
open.
dows
open.
Safe87 2012 07
Safe87
20122017
07 04
Safe57
Onlyuse
usegenerator
generatoroutside
outsideand
andfarfaraway
awayfrom
fromwindows,
windows,doors,
doors,and
and
Only
Only
use generator
outside
andinstructions
far away from
windows,
doors,
and
vents.
trained and
read the
before
working
on the
Become
vents.
vents.
machine or welding.
Safe88 2012 07
Safe88 2012 07
Safe65 2012 06
3-2.
Miscellaneous Symbols And Definitions
Donot
notuse
useether
etherororother
otherstarting
startingfluids.
fluids.Using
Usingstarting
startingfluids
fluidsvoids
voidswarranty.
warranty.See
Seeengine
engineOwner’s
Owner’sManual.
Manual.
Do
Induction heating can cause injury or burns from hot items such as rings, watches, or parts.
Amperage
Maximum Power
Consumption
Hotmuffler
muffler and exhaust pipe can cause severe burns.
Hot
Voltageand exhaust pipe can cause severe burns.Settings
Suitable For Welding In An EnvironRated Load Speed
ment With
Increased Risk Of
Electric
Shock
Welding,
cutting,drilling,
drilling,ororgrinding
grindingononbase
basecan
cancause
causefire
fireororexplosion.
explosion.
Welding,
cutting,
Direct Current (DC)
Rated No-Load
Speed
Safe89 2017 04
Safe89
2017 04
Single
Phase
Safe74
2012 07
Three Phase
Safe90 2017 04
Safe90 2017 04
Engine-Driven 3OMPhase Alternator
With Rectifier
Negative
Safe91 2017 04
Safe91 2017 04
Positive
Rated Idle Speed
Duty Cycle
Donot
notspray
spraywater
waterononCST
CSTunits.
units.
Do
Rated Welding
Current
Hertz
Protective Earth
(Ground)
Safe92 2017 04
Safe92 2017 04
Circuit Breaker
Conventional Load
Doormust
must be fully open during operation.
Door
Voltagebe fully open during operation.
Rated No-Load Voltage (OCV)
Hours
Seconds
Output
Safe93 2012 08
Safe93 2012 08
Driverolls
rollscan
caninjure
injurefingers.
fingers.Welding
Weldingwire
wireand
anddrive
driveparts
partsare
areatatwelding
weldingvoltage
voltageduring
duringoperation
operation keep
keephands
hands
On
Drive
andmetal
metalobjects
objectsaway.
away.
Clock, Time Switch
and
Current
Safe95 2012 05
Safe95 2012 05
Reduced Rated No
Load Voltage
Internal Protection
Rating
OM-281496 Page 16
Hour Meter
Alternating Current
(AC)
Increase/Decrease
Of Quantity
(Rotating)
Remote
OMOM-
3-2. Miscellaneous Symbol Definitions
3-2. Miscellaneous Symbol Definitions
A
A
V
V
Amperage
Amperage
�
Battery
(Engine)
Complete Parts List is available
at www.MillerWelds.com
Battery (Engine)
Read Operator’s
Voltage
Manual
Voltage
ReadIdle
Operator’s
(Slow)
Manual
Read
Operator’s
Manual
Negative
Welding (General)
Negative
Engine Oil
Run (Fast)
Engine Oil
Positive
Positive
Shielded
Metal Arc
Welding (SMAW)
Alternating
Current
(AC)
Alternating
Current (AC)
Gas Metal Arc
Protective
Earth
Welding
(GMAW)
(Ground)
Protective
Earth
(Ground)
Gas Tungsten Arc
Welding
(GTAW) /
Air Filter
Tungsten Inert Gas
Air Filter
(TIG) Welding
Engine Start
EngineInert
StartGas
Engine
RPM
Tungsten
(TIG)
Lift
Arc
Engine
RPM
Circuit
Breaker
Circuit Breaker
Supplementary
Protector
Supplementary
Flux
Cored Arc
Protector
Welding
(FCAW)
Direct Current
(DC)
Direct
Current
(DC)
Air Carbon Arc CuttingFuel
(CAC-A)
Fuel
Idle
(Slow)
Glow
Plug
Idle (Slow)
Engine Choke
Engine
Choke
Engine
Temperature
Temperature
Engine
Engine
Engine
Engine
Start (Engine RPM)
Engine Stop
Engine Stop
Engine Stop
Run (Fast)
Run (Fast)
Hertz Oil
Engine
Hertz
Output
Fuel
Output
U
U00
U
U22
II2
2
X
X
On
On
Engine Coolant
Percent
Percent
Engine
Coolant
Rated
No−Load
Temperature
Voltage
(OCV)
Rated No−Load
Voltage (OCV)
Conventional
Temperature
Load
Voltage
Conventional
Indication
Load Voltage
242a Rated
Current
242a
Rated
Current
Battery
(Engine)
Shielded Metal
Arc Welding
Shielded
Metal
(SMAW)
Arc
Welding
(SMAW)
Spark
Gas
MetalArrestor
Arc
Welding
(GMAW)
Gas Metal
Arc
Welding (GMAW)
Gas Tungsten Arc
Air
Filter /
Welding
(GTAW)
Gas Tungsten
Arc
Tungsten
Inert /
Welding
(GTAW)
Gas (TIG)
Tungsten
Inert
Welding
Gas
(TIG)
Welding
Check
Air Filter
Flux Cored Arc
Welding
(FCAW)
Flux Cored Arc
Welding (FCAW)
Check Pump/
Tungsten Inert
Injectors
Gas
(TIG)
Arc
TungstenLift
Inert
Gas (TIG) Lift Arc
Check Valve
Remote
Clearance
Remote
Single Phase
Certified/Trained
Alternator
Single
Phase
Mechanic
Alternator
Arc Control
Arc
Control
Arc
Control
USB
USB
USB
Push Button
Push Button
Push Button
Air Carbon
Arc
Cutting
(CAC-A)
Air Carbon
Arc
Cutting (CAC-A)
Rotating
Press Knob
Or Turn
And
Push
Button
Button
Rotating
Knob
And Push Button
Duty Cycle
Duty Cycle
Engine Belt Tension
OM-279639 Page 14
OM-279639 Page 14
OM-281496 Page 17
� 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 on back cover of this manual.
4-2.
Software Licensing Agreement
The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at https://
www.millerwelds.com/eula and are incorporated by reference herein.
4-3.
Weld, Power, And Engine Specifications
� This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C).
Engine
Generator
Power Rating
Weld Output
Range
Welding Mode
Rated Welding Output
Maximum
Open-Circuit
Voltage
Fuel Capacity
Caterpillar C1.5 Water-Cooled,
Three-Cylinder 21.7 HP Diesel
Engine
400 A, 24 Volts
DC, 100% Duty
Cycle
Single-Phase,
Complete Parts List is available
Kubota V1505 E3BG Water350at
A,www.MillerWelds.com
27 Volts
10 kVA/kW, 84/
CC/DC
20–400 A
11.5 gal
Cooled, Four-Cylinder 20.2 HP
DC, 100% Duty
84
(43.5 L)
42 A, 120/240
CV/DC
14–40 V
Diesel Engine
Cycle
2-1. Dimensions,
Weights, And Operating Angles
VAC, 60 Hz
300 A, 32 Volts
CAT Turbo C1.5T Water-Cooled,
DC, 100% Duty
Three-Cylinder 24 HP Diesel
Cycle
Engine
Complete Parts List is available at www.MillerWelds.com
G
4-4.
Dimensions, Weights, And Operating Angles
2-1. 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)
(brackets turned in)
28.75 in. (730 mm)
(brackets
A turned out)
B C
56.25 in. (1429 mm)
Depth
A
56.25 in. (1429 mm)
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)
D
9/16 in. (14 mm) Dia.
4 Holes
H
G
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Do not move or operate unit where it could
tip.
30°
A
B
C
H
Front Panel End
20°
30°
F
E
20°
H
Front Panel End
Weight
No Fuel:
Kubota: 950 lb (431 kg)
CAT: 1010 lb (458 kg)
With Fuel:
Kubota: 1032 lb (468 kg)
CAT: 1092 lb (495 kg)
30°
20°
D
20°
F
E
1
Lifting Eye Weight Rating:
2000 lb (907 kg) Maximum
4-5.
Environmental Specifications
1
A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
OM-281496 Page 18
30°
� Complete Parts List is available at www.MillerWelds.com
B.B Information
On Electromagnetic Compatibility (EMC)
C
C.
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
30°
due to conducted as well as radiated disturbances.
30°
20°
H
Temperature
Specifications
20°
Front Panel End
Operating Temperature Range*
D
Storage/Transportation Temperature Range
F
E
–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).
4-6.
Duty Cycle And Overheating
1
1 100% Duty Cycle
1
Duty cycle is the percentage of 10 minutes
that unit can weld at rated load without
overheating.
unit is rated for welding at 400 am� This
peres, 24 volts DC continuously.
NOTICE – Exceeding duty cycle can damage unit and void warranty.
400
WELD AMPHERES
A
300
200
0
10
20
30
40
50
60
% DUTY CYCLE
70
80
90
100
266504-A
OM-278215 Page 31
277791-A
OM-281496 Page 19
Complete Parts List is available at www.MillerWelds.com
Parts List is available at www.MillerWelds.com
Complete
�Parts List is available at www.MillerWelds.com
Complete
3-3. Volt-Ampere
Volt-AmpereCurves
Curves
3-3.
4-7. Volt-Ampere
Curves
Complete Parts List is available at www.MillerWelds.com
3-3. Volt-Ampere
A. Stick ModeCurves
The volt-ampere curves show the
The volt-ampere curves show the
and curve
maximum
Theminimum
volt-ampere
showsvoltage
the minimum
minimum and maximum voltage
and
amperage
output
capabilities
of output
maximum
voltage
and
The and
volt-ampere
curves
show
theamperage
and amperage
output
capabilities
of
capabilities
of the
welder/generator.
the welding
generator.
Curves of all Curves
minimum
maximum
voltage
the and
welding
generator.
Curves of all
of all
other
settings
fall between
between
other
settings
fall
the curves
and amperage
output
capabilities
of
other settings
fall between
the
shown.
curves
shown.
the welding
generator.
curves
shown. Curves of all
other settings fall between the
curves shown.
ModeMode
A.Stick
Stick
A. Stick 100
Mode
100
100
80
80
DC VOLTS
DC VOLTS
DC VOLTS
80
60
60
MIN
MIN
60
300A
300A
40 MIN
40
300A
40
20
20
20
0
00 0
0
100
100
100
0
TIGMode
Mode
B.B. TIG
200
200
300
300
200 DC AMPERES
300
400
DC AMPERES
DC AMPERES
400
400
500
500
500
B. TIG
TIG
Mode
Mode
100
100
100
80
DC VOLTS
DC VOLTS
DC VOLTS
8080
60
6060
40
4040
MIN
20 MIN
MIN
2020
0 0
00 0
0
300
300300
100100 200 200
100
200
MAX
MAXMAX
300 300 400 400 500 500
300
400
500
DC AMPERES
DC AMPERES
DC AMPERES
C. C.MIG
Mode
MIG
Mode
MAX
40
DC VOLTS
DC VOLTS
DC VOLTS
C.MIGMIG
ModeMode
60 60
60
40
40
MAX
MAX
20
20
20
MIN
MIN
MIN
0
0
00 0
0
OM-281496 Page 20
100
100
100
200
300
400
200AMPERES
300
DC
200
300
DCAMPERES
AMPERES
DC
500
400
400
500
500
266200-A
266200-A
OM-281496 Page 17266200-A
OM-281496 Page 17
OM-281496 Page 17
280
Complete Parts List is available at www.MillerWelds.com
270
2-3. AC Generator Power Curves
� Complete Parts List is available at www.MillerWelds.com
4-8.
AC Generator Power Curve
260
The AC power curve shows the generator
power in amperes.
250280
AC VOLTS
240270
260
230
250
220
AC VOLTS
240
210
230
200220
190210
200
180
190 0
20
40
60
AC AMPERES IN 240V MODE
180
0
2-4. Fuel Consumption
20
264396-A
40
60
AC AMPERES IN 240V MODE
264396-A
2-4. Fuel Consumption
Fuel Consumption
2.00
2.00
7.57
1.75
6.62
6.62
1.50
1.50
5.68
5.68
1.25
1.25
4.73
4.73
1.00
1.00
3.79
0.75
2.84
0.50
1.89
0.75
0.50
0.00
0
2.84
0.95
0.25
0.00
0
3.79
1.89
0.25
L/HR
1.75
U.S. GAL/HR.
U.S. GAL/HR.
The curve shows typical fuel use under weld
or power loads.
7.57
L/HR
4-9.
0.95
0.00
50
100
150
200
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
50
100
150
200
250
DC WELD AMPERES AT 100% DUTY CYCLE
350
300
400
250370-A
350
0.00
400
250370-A
OM-278215 Page 33
OM-278215 Page 33
OM-281496 Page 21
� Complete Parts List is available at www.MillerWelds.com
SECTION 5 – INSTALLATION
5-1.
Movement And Airflow Clearance
18 in.
18
in. mm)
(460
(460 mm)
18 in.
18
in. mm)
(460
(460 mm)
18 in.
18
in. mm)
(460
(460 mm)
18 in.
18
in. mm)
(460
(460 mm)
18 in.
18
in. mm)
(460
(460 mm)
Location/Mounting
2
2
3
4
1
1
9/16 in.
ps head
clamp
Installing Welder/Generator
crescentcom
wrench
Go to MillerWelds.
for more infor�wrench
mation on truck installations.
Movement
Do not move or operate unit where it
could tip.
� See Specifications for lifting eye rating.
Airflow Clearance
nutdriverNOTICE – Do not install unit where air flow
is restricted or engine may overheat.
chippinghammer
Location/Mounting
Always securely fasten welding generator onto transport vehicle or
trailer and comply with all DOT and
other applicable codes.
OM-281496 Page 22
wirecutter
frontcutter
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.
� Complete Parts List is available at www.MillerWelds.com
5-2. Grounding
Generator to Truck or Trailer Frame
1-1. Installing
Exhaust Pipe
1-1. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
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.
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCIprotected extension cord. Do not
use GFCI receptacles to power life
support equipment.
1 Equipment Grounding
Front Panel)
Terminal
(On
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG
or larger insulated copper wire.
bond
� Electrically
vehicle frame
generator frame to
by metal-to-metal
Exhaust1 2018 01 / Ref. 803604
contact.
For use with medium/large
export diesels
(Big Blue
500X Pro, 600 X, etc.)
5-3. Installing
Exhaust
Pipe
1-2. Installing Exhaust Pipe
Stop engine and let cool.
exhaust pipe in desired direction
� Point
but always away from front panel and
direction of travel.
Exhaust Pipe3 2018 01 / Ref. 803582
1/2 in.
philips head
wrench
crescent wrench
OM-4428 Page
1
OM-281496
Page 23
5-4.
� Complete Parts List is available at www.MillerWelds.com
Connecting The Battery
907736 / Ref. 907561 01
2-1. Connecting The Battery
+
ps head
1/2 in.
NOTICE – Lead acid batteries discharge
wrench
crescent
wrench Units that
when stored in any
temperature.
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.
nutdriver
NOTICE – Wait
two minutes after engine
chippinghammer
shutdown before disconnecting battery or
engine controller may be damaged.
clamp
wirecutter
frontcutter
OM-278739 Page 14
greasegun
filterwrench
file
OM-281496 Page 24
paintbrush
Battery is most easily accessed through the
rear panel. Remove battery access panel
from rear panel. Connect battery, negative
cable last. Reinstall battery access panel.
� 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.
� Complete Parts List is available at www.MillerWelds.com
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).
1 Full
1
OM-278215 Page 34
OM-281496 Page 25
� Complete Parts List is available at www.MillerWelds.com
1
5-6.
CAT 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).
1 Full
1
907427-6
Turbo Models
Complete Parts List is available at www.MillerWelds.com
OM-278215 Page 35
1
Ref. 907774
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.
unit has a low oil pressure shut� This
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.
OM-281496 Page 26
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).
Complete Parts List is available at www.MillerWelds.com
5-8.
� Complete Parts List is available at www.MillerWelds.com
Engine Fuel And Coolant Prestart Information
3
4
2
5
1
6
7
8
Ref: 907427 6 2
2-5. Weld Output Terminals6 Coolant Recovery Tank
Fuel
NOTICE – Do not use gasoline. Gasoline
7 Hot Full
will damage engine.
8 Cold Full
1 Diesel Fuel
1 Check coolant level in radiator before start2 Full
ing unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
Add fresh diesel fuel before starting (see enof filler neck.
gine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
� Engine stops if fuel level is low.
Coolant
3 Radiator
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.
radiator coolant level when fluid
� Check
is low in recovery tank.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze
rated to -34° F (-37° C). Add anti2
freeze 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.
4 Full
5 Capacity: 6 qt (5.7 L)
OM-278215 Page 36
Ref: 263480-A
OM-281496 Page 27
� Complete Parts List is available at www.MillerWelds.com
5-9. Weld Output Terminals
2-5. Weld Output Terminals
Ref: 263480-A
Stop engine.
2 Positive (+) Weld Output Terminal
Turn off power before connecting to
For Stick and TIG welding Direct Current
weld output terminals.
Electrode Positive (DCEP), connect elecDo not use worn, damaged, undertrode holder cable to Positive (+) terminal on
sized, or repaired cables.
right and work cable to Negative (-) terminal
on left.
1 Negative (-) Weld Output Terminal Complete
Parts List available at www.MillerWelds.com
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select type
of weld output (see Section 6-3).
5-10. Connecting Weld Output Cables
1
Stop engine.
2
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
6
not place anything between weld
� Do
cable terminal and copper bar. Make
3
OM-278215 Page 36
1
2
3
4
5
6
4
5
3/4 in. (19 mm)
ps head
clamp
2
1
wrench
crescent wrench
nutdriver
chippinghammer
OM-281496 Page 28
wirecutter
frontcutter
sure that the surfaces of the weld cable
terminal and copper bar are clean.
Correct Weld Cable Connection
Incorrect Weld Cable Connection
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.
� 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***
100 ft (30 m) or Less
Welding
Amperes
10 - 60%
Duty Cycle
AWG (mm2)
150 ft (45 m)
200 ft (60 m)
60 - 100%
Duty Cycle
AWG (mm2)
250 ft (70 m)
350 ft
(105 m)
300 ft (90 m)
400 ft
(120 m)
10 - 100% Duty Cycle 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.
Complete Receptacle
Parts List is available at www.MillerWelds.com
5-12. Connecting To Remote
Remote
Socket*
Socket Information
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.
Remote Output
Control
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.
A/V Amperage
Voltage
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
Neutral
G
Circuit common for 24 volt AC circuit.
24 Volts AC Output
(Contactor)
*The remaining sockets are not used.
all models have contactor control. See description of front panel controls and
� Not
circuit diagram.
� Accessories depend on unit capabilities.
7
9
10
11
4
3
5
OM-281496 Page 29
Complete
Parts List
is available
4-1. Front Panel Controls�
(See
Section
NO
TAG)at www.MillerWelds.com
SECTION 6 – OPERATION
6-1.
Front Panel Controls (See Section 6-2)
6
8
12
9
7
10
13 14
4
5
3
1
2
11
Ref. 275308-B
OM-281496 Page 19
OM-281496 Page 30
6-2.
� Complete Parts List is available at www.MillerWelds.com
Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
Weld Controls
Weld Meters
1 Preheat Switch
5 Remote Control Receptacle
Use switch to energize starting aid for cold
weather starting (see starting instructions
following).
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
meters also work in combination
� Weld
to display troubleshooting error codes
Use switch to start engine, select engine
speed, and stop engine.
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).
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.
With remote control connected, weld output
is determined by a combination of front panel and remote control voltage/amperage
settings.
engine hours when engine is
� Tonotcheck
running, turn Engine Control switch
If no remote control is connected to the Remote receptacle, the front panel Voltage/
Amperage control adjusts voltage and
amperage.
2 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.
best performance when welding
� For
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.
To Start:
NOTICE – Do not use ether or other starting
fluids. Using starting fluids voids warranty.
engine does not start, let engine
� Ifcome
to a complete stop before attempting restart.
Above 32° F (0° C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 32° F (0° C): 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.
not operate Preheat switch
� Do
more than 20 seconds at a time.
for
To Stop:
Turn Engine Control switch to Off position.
Engine Gauges, Meters, And Lights
�
See Section 6-13 for complete fuel,
hour,
and
engine
shutdown
information.
3 Fuel Gauge
a remote device connected to Re� Ifmote
Receptacle is faulty or is disconnected during operation, the meters
display CHEK REMT (see Section 815). Clear fault by stopping and restarting the unit or by turning Process/
Contactor switch to another position.
6 Process/Contactor Switch
(see Section 8-15).
8 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.
9 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
7 Adjust Control/Select Button
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.
Adjust Control
10 Arc Control Meter
See Section 6-3 for Process/Contactor
switch information.
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.
Arc Control setting, push
� Toandaccess
hold Adjust control for 1 second,
then release. 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.
Service Menu, push and
� Toholdaccess
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.
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
11 USB Receptacle
Allows software updates from a USB drive
(see Section 6-11). A summary file of recorded data from the unit will be saved to a
USB drive that is inserted (see Section 612).
Indicator Lights
12 Setup Light
Use gauge to check fuel level.
Illuminates when in the Service Menu.
4 Engine Service Indicator Lights
13 In Use Light
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.
Illuminates when connected to an ArcReach
accessory.
14 Arc Control Light
Illuminates when in the Arc Control settings.
OM-281496 Page 31
6-3.
� Complete Parts List is available at www.MillerWelds.com
Process/Contactor Switch
1 Process/Contactor Switch
Weld output terminals are energized
when Process/Contactor switch is in
an Electrode Hot position and the engine is running.
1
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 Output On positions for weld
output to be on whenever the engine is
running.
Output On
Use the Lift-Arc TIG mode for TIG (GTAW)
welding using the Lift-Arc TIG starting
procedure.
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.
1
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)
Remote On/Off
Required
Output On – CAC-A (Air Carbon Arc
Gouging)
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.
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-281496 Page 32
Complete Parts List is available at www.MillerWelds.com
1-1. Service
ServiceMenu
Menu
6-4.
� Complete Parts List is available at www.MillerWelds.com
1
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
the control
to access the op1 Adjustrelease
Control/Select
Button
tions and information within each
menu item.
Press and hold control for 5 seconds, then reRotate the control
lease to access
Servicecounterclockwise
Menu. Rotate the
to decrease
oritems.
select Press
NO/
knob to scroll
throughthe
thevalue
menu
OFF.the
Rotate
thetocontrol
clockwise
to
and release
control
access
the options
and information
within
each menu
item.YES/
increase
the value
or select
ON.
Rotate the control counterclockwise to dePress
andor
release
to save
secrease the
value
selectcontrol
NO/OFF.
Rotate
lection.
After to
5 seconds
inactivity,
the control
clockwise
increaseofthe
value or
the menu will time out and the selecselect YES/ON.
tion will not be saved.
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
(Only accessible in SMAW
processes)
LIMT OFF
Disables Hot Start option.
LIMT 0.50
Sets time the current transitions from hot start to the preset current.
Factory preset is 0.5 seconds for both XX10 and XX18. Range is 0 to
1 second settable in 0.1 second increments.
AUTO CRTR
(Only accessible in GTAW
processes)
ATCR ON
Enables Auto Crater option.
ATCR OFF
Disables Auto Crater option.
DIG RNGE
0–150
Sets current limit above preset amperage between 0 and 150 amps
for XX10 or 0 and 50 amps for XX18.
HOUR MTR
––
Displays engine hours.
OIL HOUR
––
Displays remaining oil change hours before service is due.
OIL SET
50 HRS
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
Sets the starting hours for oil change period. Selectable from 50-1500
hours in 50 hour increments.
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.
OM-281496 Page 1
OM-281496 Page 33
6-5.
� Complete Parts List is available at www.MillerWelds.com
Arc Control Settings
Control is not active when the Process/Contactor switch is in the following positions:
� Arc
Output On: CAC-A (Air Carbon Arc Gouging)
Remote ON/OFF: GTAW (Remote TIG)
Process/Contactor Switch
Complete Parts List is available at w
Complete Parts List is available at w
Arc Control
SOFT
(25 to 1)
Starting
Starting point
point for
for stainless
stainless steel
steel wire
wire (high inductance)
Starting point for stainless steel wire (high inductance)
� (0)
Starting point
point for
for mild
aluminum
wire (low inductance)
Starting
steel wire
Starting point for aluminum wire (low inductance)
Starting point for aluminum wire (low inductance)
STIFF
(1 to 25)
Flat or horizontal welds with XX18 electrode with short weld cables
Flat or horizontal welds with XX18 electrode with short weld cables
Voltage sensing feeder
STOP
(–5 to –1)
Starting point for aluminum wire (low inductance).
Starting point for aluminum wire (low inductance).
Auto-Crater
Service Menu). More sensitive Auto-Stop
off (see STOP
(1 to 5)
Starting point.
point for dual shield flux core, vertical overhead
Starting
Starting point for dual shield flux core, vertical overhead
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 Service Menu). More sensitive Auto-Crater initiation.
� (0)
Starting point
STOP
(1 to 5)
Less sensitive Auto-Crater initiation
� (0)
SOFT
(25 to 1)
� (0)
Starting point
Complete Parts List is available at w
STIFF
(1 to 25)
Starting point for stainless steel wire (high inductance)
Starting point for aluminum wire (low inductance)
Complete Parts List is available at w
Complete Parts List is available at w
SOFT
(25 to 1)
Starting
point
steel
wire
(high inductance)
Starting
point for
for stainless
stainless
steel
wire
Flat
or horizontal
welds
with
XX18
electrode
with short weld cables
Starting point for stainless steel wire (high inductance)
� (0)
Starting point
point for
for mild
aluminum
wire (low inductance)
Starting
steel wire
Starting
Starting point
point for
for aluminum
aluminum wire
wire (low
(low inductance).
inductance)
Starting point for aluminum wire (low inductance)
STIFF
(1 to 25)
Flat or horizontal welds with XX18 electrode with short weld cables
Starting point for dual shield flux core, vertical overhead
Starting
overhead
Flat or horizontal welds with XX18 electrode with short weld cables
Wire feeder connects to Remote receptacle
OM-281496 Page 34
Starting point for aluminum wire (low inductance).
Starting point for aluminum wire (low inductance).
Starting point for dual shield flux core, vertical overhead
Starting point for dual shield flux core, vertical overhead
6-6.
� Complete Parts List is available at www.MillerWelds.com
Dynamic Dig Settings
Process/Contactor Switch
Arc Control
Process/Contactor Switch
SOFT
(25 to 1)
Softer, slower responding arc
� (0)
Starting point for XX10 electrode/open root vertical down joint
STIFF
(1 to 25)
Stiffer, more rapidly responding arc
Dig Range XX10
Process/Contactor Switch
(0)
Softer arc that minimizes or eliminates undercut
(100)
Starting point for downhill pipe (factory default)
(150)
Stiffer arc with greater penetration
Dig Range XX18
(0)
Softer arc that minimizes or eliminates undercut
(25)
Starting point for all XX18 welding applications
(50)
Stiffer arc with greater penetration
Arc Control
SOFT
(25 to 1)
Softer, slower responding arc
Complete Parts�List(0)is available Starting
at www.MillerWelds.com
point for XX10, XX11, XX13, XX14, XX18, XX24, and
electrodes
Complete Parts List is available XX22
at www.MillerWelds.com
STIFF
Dig RangeStiffer, more rapidly responding arc
(1 to 25)
Dig Range
Dig(0)
Range
Starting point for XX18 rod
(0) (0)
Starting
XX18 rod
Starting
point for
point
(100)
(100)
Starting
default)
Starting point
point for downhill pipe (factory default)
(100)
Starting
downhill pipe
(factory default)
point for
(150)
(150)
6-7.
(150)
Stick Start Procedure—Scratch Start Technique
OM-278215 Page 38
With Stick selected, start arc as follows:
1
1 Electrode
OM-278215 Page 38
2 Workpiece
3 Arc
2
3
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.
� Miller recommends Hobart filler metals.
1
2
OM-281496 Page 35
3
6-8.
� Complete Parts List is available at www.MillerWelds.com
Lift-Arc™ TIG With Auto-Stop™ And Auto-Crater™
1
Arc Start With
Lift-Arc
1
2
Arc Start With Lift-Arc TIG
2
Lift-Arc is used for the DCEN GTAW process
when HF Start method is not permitted.
Select Lift-Arc at Process/Contactor switch.
Turn gas on.
1. Touch or scratch.
2. Lift at any angle.
1
Arc End With Auto-Stop
1
2
3
2
3
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. While welding.
2. Lift torch to start Auto-Stop. Arc stops.
3. Move torch back down to maintain gas
coverage and prevent contamination.
Arc End With Auto-Crater
Arc End With Auto-Crater
1
2
3
4
control is not needed when us� Remote
ing Auto-Crater.
1
2
3
4
1. While welding.
2. Lift torch slightly to start Auto-Crater end
(current is reduced).
3. Lower torch. Weld current ramps down.
4. Shielding gas continues until shut off.
� Miller recommends Hobart filler metals.
OM-281496 Page 36
6-9.
� Complete Parts List is available at www.MillerWelds.com
Remote Voltage/Amperage Control
Complete Parts List is available at www.MillerWelds.com
Complete Parts List available at www.MillerWelds.com
Complete Parts List available at www.MillerWelds.com
1
1-1.
Voltage/Amperage
Control
With
14-Pin
Remote
Accessory
1-1. Voltage/Amperage Control With 14-Pin Remote Accessory
1
2
Big Blue 8002Duo Air Pak shown.
Big Blue 800 Duo Air Pak3 shown.
2
3
1
3
1
1
CC Welding
56
56
205
205
1 Remote Receptacle
Connect optional remote control to receptacle (see Section 5-12).
Remote Receptacle
1 Remote
WhenReceptacle
a remote control is connected to
Connect optional remote control to
Connectthe
optional
remote
control to the Auto ReRemote
receptacle,
receptacle.
receptacle.
mote Sense feature automatically
voltage/amperage
control to
Whenswitches
a remote control
is conWhen a remote control is concontrol.
When a device is
nectedthe
to remote
the Remote
recepnected to the Remote receptacle, connected
the Auto Remote
to theSense
Remote receptacle,
tacle, the Auto Remote Sense
feature
automatically
switches
remote
voltage/amperage
feature
automatically
switches control is alvoltage/amperage
control
to the
ways available
regardless
voltage/amperage
control
to the of the posiremote
control.
When
a device is
tion
of the
Process/Contactor
switch.
remote
control.
When a device is
connected to the Remote recepconnected to the Remote recepremote voltage/amperage
2tacle,
Voltmeter
tacle, remote voltage/amperage
control is always available recontrol is always available reof the position of the
3gardless
Ammeter
gardless of the position of the
Process/Contactor switch.
Process/Contactor switch.
Welding
2 CC
Voltmeter
2 Voltmeter
3 Ammeter
3Connect
Ammeter
remote control to remote recepCC tacle.
Welding
Set TIG or STICK process.
CC Welding
Connect remote control to remote reConnect remote control to remote receptacle.
TIG orcontrol
STICK process.
Turn Set
remote
On. Adjust optional receptacle. Set TIG or STICK process.
control
to On.
100%.
Turnmote
remote
control
Adjust opTurn remote control On. Adjust optional remote control to 100%.
tional
remote shows
control to
100%.
Voltmeter
open-circuit
voltage when
Voltmeter
shows arc
open-circuit
volt- welding.
not welding,
voltage while
Voltmeter
shows open-circuit
voltage when not welding, arc voltage
age when not welding, arc voltage
while welding.
Ammeter
while
welding.shows preset output when not
Ammeter
shows
preset
output when
welding,
actual
amperage
while welding.
Ammeter
shows
preset
output when
not welding, actual amperage while
not welding, actual amperage while
welding.
Set V/A control to desired maximum weld
welding.
using
weld meters.
Set output
V/A control
to desired
maximum
Set V/A control to desired maximum
weld output using weld meters.
weld
output
using
weld
meters.control to desired
Adjust optional remote
Adjust optional remote control to deAdjust
optional
remote
control
to deweld
output
(max
205
A DC,
min 20 A DC).
sired weld output (max 205 A DC,
sired weld output (max 205 A DC,
min 20 A DC).
min
A DC).
CV20
Welding
CV Welding
CV Welding
Connect
to remote recepConnect
remoteremote
control tocontrol
remote reConnect
remote
control
to remote retacle.Set
Set
WIRE
process.
ceptacle.
WIRE
process.
ceptacle. Set WIRE process.
Output
On: Voltmeter
toggles
beVoltmeter
between
and actual
Output
On: toggles
Voltmeter
toggles preset
between preset and actual output when
tween
preset
and actual
output when
output
when
not
welding,
not welding, actual voltage while actual voltage
not
welding,
actual voltage while
while
welding.
welding.
welding.
Remote
On/Off
Required:
Ammeter
shows
zero.Voltage
Remote
On/Off
Required:
Voltage
shown is preset.
shown is preset.
Turn shows
remotezero.
control On. Adjust optional reAmmeter
Ammeter shows zero.
mote control to desired weld output.
Adjust optional remote control to deAdjust optional remote control to desired weld output.
sired weld output.
�
CV Welding
28
28
00
0774 / Ref.272 446-B / Ref. 907 695
0774 / Ref.272 446-B / Ref. 907 695
OM-281496 Page 37
OM-279640 Page 1
OM-279640 Page 1
� 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.
Do not run engine while engine
block heater is on.
NOTICE – In extremely cold weather, heater
should be connected to power source when
engine is warm.
The area near the engine block
heater gets hot.
Disconnect plug to turn off heater.
Heater Specifications
Engine
1
OM-281496 Page 38
Watts
Volts ±10%
Kubota
400
120
CAT
1000
120
Complete Parts List is available at www.MillerWelds.com
4-2. Updating Software �
6-11. Updating Software
Complete Parts List is available at www.MillerWelds.com
1
Obtain the latest firmware to be loaded from
MillerWelds.com
Copy the desired firmware to an approved
USB flash drive.
Obtain
the latestturned
firmware
to be the
loaded
With
the machine
off, insert
flash
frominto
MillerWelds.com.
drive
the USB receptacle on the front of
the machine. Turn the Engine Control switch
toCopy
the Run
Run/Idle
position.
the or
desired
firmware
to an approved
USB flash drive (see Section NO TAG).
Do not start the engine.
�
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.
When the
machinethe
hasAdjust
powered
up, if valid
Confirm
by rotating
Control/Select
button
clockwise
selectdrive,
YES.the
Then
files exist
on thetoflash
userpress
is
the
Select button.
prompted
to confirm the start of the download. The Voltmeter/Ammeter display
reads:
AL?
NO.
After
the
update has started, do not
down or remove
the flash drive
1 power
Adjust Control/Select
Button
until by
therotating
updatethe
is complete.
Confirm
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.
During the download, the left meter display
When
the the
update
has
completed
indicates
active
download
withsuccessALLC,
fully,
the AL
machine
restarts.
ALLW,
C, or AL
W. The right meter display indicates the percentage of the downFailures
are indicated
the meter
load completed
with aonnumber
fromdisplay.
0 to
Correction
of failed updates depends on
100.
what type of failure occurred.
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-281496 Page 20
OM-281496 Page 39
Complete Parts List is available at www.MillerWelds.com
4-3. Summary File
6-12. Summary File
� Complete Parts List is available at www.MillerWelds.com
1
1
Summary File
Each time a USB stick is inserted
1 Summary File
in the USB receptacle, a summary file is saved to the USB stick as
Each time
a USB stick is inserted in the USB
SummaryFile.txt.
receptacle, a summary file is saved to the
“USB
will display as the file
USB stick
asACC”
SummaryFile.txt.
is written. File is complete when
"USB ACC"
the file“USB
is written.
displaywill
nodisplay
longerasshows
File isACC.”
complete when display no longer
shows "USB ACC."
The summary file provides diagnostic andfile
weld
information.
The summary
provides
diagnostic and
weld information.
OM-281496 Page 21
OM-281496 Page 40
11-25.
Fuel/Hour�
Gauge Descriptions
6-13. Fuel/Hour Gauge Descriptions
Complete Parts List is available at www.MillerWelds.com
OM-281496 Page 41
� 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
For Stick Or TIG Welding
ArcReach SuitCase Feeders
For MIG Or FCAW Welding
ArcReach Smart Feeder
For Advanced Wire Processes
274460-A / 266206-D
274460-A / 266206-D
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.
OM-281496 Page 42
When welder/generator is associated with
Suitcase X-TREME ArcReach feeder, voltage
and wire feed settings are adjusted on the
feeder.
274460-A / 266206-D
When welder/generator is associated with
Smart Feeder, all controls switch to the
feeder, and the display reads SMRT ACC.
using an ArcReach device, en� When
gine speed is always weld/power
speed.
Complete Parts List is available at www.MillerWelds.com
Parts List is available AUXILIARY
at www.MillerWelds.com
SECTION 5� Complete
OPERATING
EQUIPMENT
SECTION 7 – OPERATING AUXILIARY EQUIPMENT
5-1. Auxiliary Power Receptacles
7-1. Auxiliary Power Receptacles
1
2
3
7
265602-A
6
4
5
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCIprotected extension cord. Do not
use GFCI receptacle to power life
support equipment.
ELCB1 protects receptacle RC11 from overload and earth leakage fault. If circuit breaker opens, the receptacle does not work.
Place switch in On position to reset circuit
breaker.
Unplug power cord before attempting to service accessories or tools.
5 Earth Leakage Circuit Breaker ELCB2
1 220V 16A AC Receptacle RC11
2 110V 20 A AC Receptacle GFCI1
3 220V 32 A AC Receptacle RC12
Receptacles supply 50/60 Hz single-phase
power.
Maximum combined output of all receptacles is 10 kVa/kW.
ELCB2 protects receptacle RC12 from overload and earth leakage fault. If circuit breaker opens, the receptacle does not work.
Place switch in On position to reset circuit
breaker.
6 Supplementary Protector CB5
CB5 protects the stator windings from overload. If supplementary protector opens, the
receptacles do not work. Reduce load and
place in On position.
CB4 protects GFCI1 from overload. If supplementary protector opens, the receptacle
does not work. Press button to reset.
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
least once a month, run engine at
� Atweld/power
speed and press test button to verify ELCBs are working
properly.
a supplementary protector or circuit
� Ifbreaker
continues to open, contact
Factory Authorized Service Agent.
power decreases as weld
� Generator
output increases.
4 Earth Leakage Circuit Breaker ELCB1
7 Supplementary Protector CB4
OM-281496 Page 22
OM-281496 Page 43
7-2.
� Complete Parts List is available at www.MillerWelds.com
GFCI Receptacle Information, Resetting, And Testing
6
1
2
5
4
3
1
2
3
4
5
6
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCIprotected 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)
Alternate Location For Red And Green
Indicator LEDs
and Green indicator lights may be
� Red
combined in a single LED.
of receptacle may be differ� Orientation
ent in other applications.
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-281496 Page 44
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/Testing GFCI Receptacle
Test GFCI monthly.
If Red LED blinks, stop using GFCI
receptacle and have a Factory Authorized Service Agent replace it.
Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
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 engine control 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.
Testing GFCI Receptacles
Start engine and place engine control switch
in Run position. Press the GFCI Test button.
The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have a Factory Authorized Service Agent
replace GFCI 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
Complete Parts List is availableAND
at www.MillerWelds.com
SECTION 8 – MAINTENANCE
TROUBLESHOOTING
1-1. CAT Maintenance Label
8-1. CAT Maintenance Label
237362-J
OM-278215 Page 1
OM-281496 Page 45
Complete Parts List is available at www.MillerWelds.com
8-2.
� Complete Parts List is available at www.MillerWelds.com
Kubota Maintenance Label
j
OM-278215 Page 43
OM-281496 Page 46
� Complete Parts List is available at www.MillerWelds.com
e Engine Checks
8-3.
Routine This
Maintenance
flowchart is intended as a general guide only. Al-
ways read and follow the safety information and specific
instructions given elsewhere in this Technical Manual.
ervicing a Miller gasoline-powered welder/generator, always perform the following basic
engine checks before contacting the engine manufacturer.
e a Kohler-authorized service agency, visit https://kohlerpower.com/en/engines/dealers.
Stop engine before maintaining.
To check oil level, see Section __.
Engine
Manual
andswitch
Maintenance
Label for important start-up, service, and storage information. Service engine more often if used in
BasicTrouble:
Gasoline
Checks
Oil level�
isEngine
tooSee
low. Symptom:
Oil pressure
will
not close. The engine will
begin toconditions.
start and then stop.
severe
This flowchart is intended as a general guide only. Always read and follow the safety information and specific
instructions given elsewhere in this Technical Manual.
Trouble: Oil level is too high. Symptom: The pressure line that
operates the fuel pump Recycle
can be plugged.
Notfluids.
enough fuel will be
engine
delivered, and the engine will not run or will run poorly.
�
◇
= Change
� = Clean
� = Replace
Complete Parts List is available
at www.MillerWelds.com
� = Check
Reference
When servicing a Miller gasoline-powered welder/generator, always perform the following basic
To check fuel level,
see Section
__. checks before contacting the engine manufacturer.
engine
Every
Complete Parts List is available at www.MillerWelds.com
Engine
Manual,
Sections
5-8, 5-6, 55, 8-9
is available
at www.MillerWelds.com
Trouble: Fuel level
will Complete
Complete
PartsParts
List isList
available
at www.MillerWelds.com
8 is too low. Symptom: The fuel pump
locate
a Kohler-authorized
service
have noTo
fuel
to feed
the engine, and the engine
willagency,
not startvisit
or https://kohlerpower.com/en/engines/dealers.
Hours
stay running.
List is available at www.MillerWelds.com
Trouble: Fuel level is too high.
Symptom:
Fuelsee
will Section
plug the fuel
To check
oil level,
__.Complete Parts
Complete Parts List is available at www.MillerWelds.com
vent and flood the engine. The engine will not start or will run
Complete
Parts
List at
is www.MillerWelds.com
available
at www.MillerWelds.com
Complete
List switch
isList
available
Trouble:
Oil level is too low. Symptom:
OilParts
pressure
Complete
Parts
iswill
available
at www.MillerWelds.com
poorly and have black smoke
in the exhaust.
not�close.
The Level
engine will begin to start
and then
stop.
Coolant
� Fuel
Level
Complete Parts List available at www.MillerWelds.com� Oil Level
Oil Level
� Oil, Fuel Spills
Trouble: Oil level is too high. Symptom: The pressure line that
Every filters, seethe
fuel __.
pump can be plugged. Not enough fuel will be
To check
and replace fuel operates
Section
Every
100
delivered, Fuel
and flow
the engine
will not
100Dirty fuel filters. Symptom:
Trouble:
to the engine
is run or will run poorly.
Section 8-4
Hours
restricted.
EngineHours
will not run or run well if it is starved for fuel.
NOTICE EFI engines have two fuel filters. Use the correct filters to
prevent damage to the EFI fuel pump and injectors. See Section __.
Terminals
BatteryTo
Terminals
Weld
check fuel level,see
Section
__.
Element
Air Cleaner
Complete Parts List is available
at www.MillerWelds.com
� Battery
� Air The
Cleaner
Hoses
Trouble:
Fuel and
levelWeld
is too low. Symptom:
fuel pump
will
have
no fuel to feed the engine, and the engine will not start or
Terminals
stay running.
Fuel Level
Every
Hours
Kubota,
To check and replace
air250
filters,
see Section
__. isCAT
Trouble:
Fuel level
too high. Symptom: Fuel will plug the fuel
– Change
engine
oil and
Trouble: Dirty airNOTICE
filters. Symptom:
flow
to the
engine
vent
and Air
flood
the
engine.
The filengine will not start or will run
is restricted. Engine
start
hard,and
notto
run,
have black
ter will
after
initial
50
75orblack
hours
of use.
poorly
have
smoke
in the exhaust.
smoke in the exhaust if it is not getting enough air.
� Air Cleaner Element
To check and replace fuel filters, see Section __.
Engine
Manual,
Sections FUEL
8-6, 8-14
1/2 in.
(13 mm)
1/2 in. 1/2 in.
(13 mm)
(13 mm)
◇ Oil and Oil Filter
Every
500
� Unreadable Labels
1/2 in.
(13 mm)
1/2 in.
(13 mm)
1/2 in.
�1/2
Fan
Belt
(13
in.
1/2 mm)
in.1/2
in. Tension
Trouble:
Dirty
fuel __.
filters. Symptom: Fuel flow to the engine is
To check and replace spark
plugs, see
Section
restricted.
Engine willSpark
not run or run well if it is starved for fuel.
worn spark
plugs. Symptom:
FuelTrouble:
FiltersSeverely
Hours
plugs will not ignite the air NOTICE
and fuel mixture.
Engine will
starttwo fuel filters. Use the correct filters to
EFI engines
have
hard and run very rough. prevent damage to the EFI fuel pump and injectors. See Section __.
If spark plugs are black, dry, or wet, there is a problem with
fuel or air delivery. See previous steps.
� Weld Cables
� Radiator, Thermostat
SLUDGE
SLUDGE
Sections 511, 8-2, 8-1,
8-14FUEL
FUEL
FUEL FUEL
FUEL
SLUDGE
SLUDGE
SLUDGE
�
Drain
Sludge
SLUDGE
SLUDGE
SLUDGE
◇� Fuel Filter(s)
1/2 in.
(13 mm)
Every
To check battery1000
voltage, see
Sectionand
__. replace air filters, see Section __.
To check
Hours
Trouble: Battery voltage is too low. Symptom: Control
Engine
Manual,
Sections
FUEL
5-8,
8-7
Trouble: Dirty air filters. Symptom: Air flow to the engine
Air boards
Filters
and the EFI ECU require 12 volts DC to operate.
is restricted. Engine will start hard, not run, or have black
Low voltage from a defective battery or charging circuit can
smokespeed
in theand
exhaust
if it is not getting enough air.
cause improper or erratic engine
weld output.
� � Slip Rings*
� � Brushes*
� Valve Clearance*
FUEL
� � Spark Arrestor
FUEL
FUEL
SLUDGE
(13 mm)
(13 mm) (13 mm)
� Inside Unit
� Radiator Fluid Level
SLUDGE
Every
2000 To check and replace spark plugs, see Section __.
Hours Trouble: Severely worn spark plugs. Symptom: Spark
To perform the ECU Reset and TPS Learn procedures, see Section __.
In EFI systems, the ECU learns the air and fuel mixture that it needs to
will not
the
airmixture
and fuel
mixture. Engine will start
regulate.
When somethingplugs
that affects
theignite
air and
fuel
changes
Spark
Plugs
OM-249336 Page 1
hardorand
run
very the
rough.
(such as fuel filters, air filters,
spark
plugs),
ECU and TPS reset
�orInjectors*
procedures must be performed
the engine will not run well when warm.
If spark plugs are black, dry, or wet, there is a problem with
fuel or air delivery. See previous steps.
*To be done by factory authorized service agent.
Gasengine_2018-11
OM-249336 Page 1
Battery Voltage
Kubota To
Engine
America
check battery voltage, see Section __.
505 Schelter Road
Trouble:
Battery voltage is too low. Symptom: Control
Lincolnshire,
IL 60069
Caterpillar Corporate Headquarters
100 North East Adams Street
Peoria, IL 61629
voltage fromFax:
a defective
battery or charging circuit can
Phone: Low
847-955-2500
847-955-2699
309-675-1000
boards and the EFI ECU require 12 volts DC to operate.
cause improper or erratic engine speed and weld output.
To find a service facility near you, contact the
KEA distributor in your area: http://www.kubotaengine.com/
https://www.cat.com/engines
OM-249336 Page 1
Cat Dealer Locator: Use website to find local
engine service facility.
To perform the ECU Reset and TPS Learn procedures, see Section __.
EFI Engines:
ECU Reset/
TPS Learn
In EFI systems, the ECU learns the air and fuel mixture that it needs to
OM-249336 Page 1
regulate. When something that affects the air and fuel mixture changes
(such as fuel filters, air filters, or spark plugs), the ECU and TPS reset
procedures must be performed or the engine will not run well when warm.
Gasengine_2018-11
OM-281496 Page 47
OM-249336 Page 1
8-4.
� Complete Parts List is available at www.MillerWelds.com
NOTE:
This standard
is now used for IED/PED models with plastic air cleaner housing.
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.
air cleaner primary element can be
� The
cleaned but the dirt holding capacity of
4
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.
1
2
3
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.
5
6
7
1 Intake Manifold
8
2 Service Indicator (Optional, Customer
Supplied)
3 Service Indicator Window
4 Service Indicator Reset Button
9
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.
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.
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 elOM-480 Page
1
ement. Replace primary
element
if it has
holes or damaged gaskets.
Reinstall primary element and cover (dust
ejector down).
OM-281496 Page 48
minimum length. Check length from
brushholder surface.
8-5.
� Complete Parts List is available at www.MillerWelds.com
Checking Generator Brush Assembly
1
1
4
3
2
Ref 205725
4 Damaged Brush
Stop engine and let cool.
1 Generator Brush Assembly
2 Minimum Length: 1/4 in. (6.5 mm)
Mark and disconnect leads at brushholder
assembly. Remove assembly. Press on
brush to be sure springs compress.
Replace assembly if brushes are damaged
or if brush material is at or near minimum
length. Check length from brushholder
surface.
3 New Length: 5/8 in. (16 mm)
8-6.
Inspecting And Cleaning Optional Spark Arrestor Muffler
Complete Parts List is available at www.MillerWelds.com
OM-255 254 Page 1
Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt covering
cleanout hole.
3 Exhaust Pipe
3
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.
Stop engine and let cool.
1
Reinstall cleanout plug.
2
3/8 in.
philips head
wrench
crescent wrench
1
OM-281496 Page 49
8-7.
� Complete Parts List is available at www.MillerWelds.com
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
8-8.
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.
8-9.
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.
OM-281496 Page 50
OM-236 948 Page 1
� Complete Parts List is available at www.MillerWelds.com
8-10. CAT Engine Speed Adjustment
Complete Parts List is available at www.MillerWelds.com
Stop engine and let cool.
Engine Speed Adjustment
4
After tuning engine, check engine speed with
tachometer or frequency meter. See table for
proper no load speed. If necessary, adjust
speed as follows:
NOTICE – Start engine and run until warm.
Maximum no load speed must be set with
engine warmed up.
Turn Process/Contactor switch to Stick Weld Terminals Always On position.
1 Throttle Rod / Plunger
2 Lock Nut
3 Rubber Boot
4 Adjustment Screw
Adjustment screw is not used to adjust engine speed when automatic idle option is
installed.
solenoid damage, be sure a
� To1/8prevent
in. (3 mm) gap exists between the
engine low speed screw and throttle
lever when the solenoid is held in the
energized position.
Unhook rubber boot from the solenoid housing but leave connected to plunger.
Loosen lock nut. Place Engine Control
Switch in Auto position.
2
Turn throttle rod and plunger until engine
runs at idle speed. Tighten lock nut.
1
Hook rubber boot back onto solenoid
housing.
sure solenoid plunger pulls all the
� Be
way in ("bottoms") when energized.
Weld/Power Speed Adjustment
speed adjustment must be
� Weld/power
done by the engine manufacturer’s factory authorized service agent. Tampering with adjustments other than shown
may affect engine warranty.
Stop engine.
3
Engine Speed (No Load)
803 563
1890 RPM Max (63 Hz)
1500 RPM (50 Hz)
8-11. CAT Turbo Engine Speed Adjustment
NOTICE – Engine speed is not adjustable. Attempting engine speed adjustment may affect warranty.
OM-281496 Page 51
� Complete Parts List is available at www.MillerWelds.com
8-12. Kubota Engine Speed Adjustment
3
4
1
5
Stop
3
NGO’s
O’s
knife
eelbrush
ch
2
tools/
ols/
Loosen
nut. Turn
high speed
Stop engine and let cool.
flathead
head
wrench
wrenchadjustment
crescent
philips
head
wrenchphilipscrescent
wrench
screw until engine runs at weld/power
Engine speed is factory set and should not
speed. Tighten nut.
require adjustment. After tuning engine,
check engine speed with tachometer or freLow speed adjustment screw is not used to
quency meter. See table for proper no load
adjust engine speed when automatic idle
speed. If necessary, adjust speed as option is installed. To prevent solenoid damfollows:
age, be sure a 1/8 in. (3 mm) gap exists between the engine low speed screw and the
Start engine and run until warm.
throttle lever when the solenoid is held in the
energized position.
steelbrush
nutdriver
nutdriver
Turn Process/Contactor
switch to Stick Weld Terminals Always On position.
chippinghammer
Adjust length ofchippinghammer
the throttle solenoid rod until
engine runs at idle speed.
1 High Speed Adjustment Screw
3 Lock Nut
not set engine speed higher than
� Do
specified.
4 Throttle Solenoid Rod
5 Engine Stop Lever
2 Low Speed Adjustment Screw
heavy-duty
workclamp
light-duty
workclamp
light-duty workclampfrontcutter
wirecutter
wirecutter
frontcutter
OM-281496 Page 52
drill
greasegun
greasegun
filterwrench
filterwrench
Use lever to stop engine.
Stop engine.
Close door.
Engine Speed (No Load)
1890 RPM max (63 Hz)
1500 RPM (50 Hz)
OM-278215 Page 45
� Complete Parts List is available at www.MillerWelds.com
8-13. Overload Protection
Complete Parts List is available at www.MillerWelds.com
Stop engine.
a circuit breaker, supplementary
� When
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 Circuit Breaker CB1 (Not Shown)
3 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.
1
3
6
4
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.
CB8 protects the 24 volt AC output to remote
receptacle RC14. If CB8 opens, 24 volt output to RC14 stops.
Press button
protector.
5
OM-278215 Page 46
to
reset
supplementary
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.
OM-281496 Page 53
Complete Parts List is available at www.MillerWelds.com
Complete Parts List is available at www.MillerWelds.com
� Complete Parts List is available at www.MillerWelds.com
8-14. 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 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter
5 Secondary Fuel Filter
6 Fuel Tank Sludge Drain Valve
7 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.
6
Section 6-4 to reset the oil change
� See
hours following service.
2
6
2
4
CAT Engine
3
4
3
5
5
803 563 / Ref 214 777 E
1
803 563 / Ref 214 777 E
1
OM-278215 Page 47
OM-278215 Page 47
OM-281496 Page 54
Complete Parts List is available at www.MillerWelds.com
Parts
List is
available
at www.MillerWelds.com
Complete
Complete
Parts
List
is available
at www.MillerWelds.com
�
1-1. Connecting The Battery
Kubota Engine
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
3
Fill new filter with fresh fuel. Apply thin coat of
fuel to gasket on new filter.
4
Install new filter and turn clockwise.
Bleed air from fuel system according to engine manual.
+
7
Inspect fuel lines, and replace if cracked or
worn.
5
To drain water from fuel system:
See engine manual.
7
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:
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.
1
CAT Turbo Engine
4
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining
fuel tank.
3
7
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.
5
7
Close door.
3
7
5
7
NGO’s
tools/
1
NGO’s
tools/
et
ead
NGO’s
allen_wrench
1
flathead
philips head
wrench
7
pliers
needlenose
head
wrench
crescent wrenchknife
wrenchphilipscrescent
wrench
steelbrush
nutdriver
chi
OM-281496 Page 1
knife
steelbrush
steelbrush
nutdriver
c
4
tools/
flathead
OM-278215
Page 48
philips
head
allen_set
nutdriver
solderiron
chippinghammer
heavy-duty workclamp
stripcrimp
chippinghammer
OM-281496 Page 55
light-duty workclamp
wirecutter
� Complete Parts List is available at www.MillerWelds.com
8-15. Voltmeter/Ammeter Error Displays
Display Example
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions.
� 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. 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.
BOOT ERR
Slave processor(s) not reporting versions. Reload software.
OM-281496 Page 56
� Complete Parts List is available at www.MillerWelds.com
8-16. Troubleshooting Tables
� Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-15).
A. Welding
Trouble
Remedy
No weld output; generator power output okay at AC receptacles.
Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and turn remote contactor on (see Section 5-12).
Reset supplementary protector CB8 (see Section 8-13). 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 8-15).
No weld output, or generator power
output at AC receptacles.
Disconnect equipment from generator power receptacles during start-up.
Reset supplementary protector CB3. (see Section 8-13).
Check fuse F1, and replace if open (see Section 8-13). If F1 is open, have Factory Authorized Service Agent check the field excitation circuit.
Check Voltmeter/Ammeter error displays (see Section 8-15).
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 8-13). If F1 is open, have Factory Authorized Service Agent check the field excitation circuit.
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
receptacle.
Reset supplementary protector CB8 (24 volt) (see Section 8-13).
B. Generator Power
Trouble
Remedy
No generator power output at AC receptacles; weld output okay.
Reset receptacle supplementary protector(s) (see Section 7-1). Check and reset GFCI receptacle if
necessary (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 8-13). Have Factory Authorized Service Agent
check field excitation circuit.
Reset supplementary protector CB3 (see Section 8-13).
Check Voltmeter/Ammeter error displays (see Section 8-15).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC
receptacles.
Have Factory Authorized Service Agent check field excitation circuit.
Low output at generator power AC
receptacles.
Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 8-13). If F1 is open, have Factory Authorized Service Agent check the field excitation circuit.
OM-281496 Page 57
� Complete Parts List is available at www.MillerWelds.com
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 813). Have Factory Authorized Service Agent check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-13).
Check engine wiring harness plug connections.
Check Voltmeter/Ammeter error displays (see Section 8-15).
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
plugs.
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 8-15).
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 813). Reset supplementary protector CB2 (see Section 8-13). Have Factory Authorized Service Agent
check engine alternator, engine harness, 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 8-15).
Check engine air and fuel filters (see Sections 8-4 and 8-14).
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 and current transducer HD1.
Check Voltmeter/Ammeter error displays (see Section 8-15).
Engine does not run at idle speed.
Have Factory Authorized Service Agent check control relay CR4, circuit breaker CB9, and throttle
solenoid TS1.
Check Voltmeter/Ammeter error displays (see Section 8-15).
Engine uses oil during run-in period;
wetstacking occurs.
OM-281496 Page 58
Dry engine according to run-in procedure (see Section 11).
� Complete Parts List is available at www.MillerWelds.com
SECTION 9 – PARTS LIST
9-1.
Item No.
Recommended Spare Parts
Dia. Mkgs. Part No.
276418
F1
Description
Quantity
USB Flash Drive
1
085874
Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt
1
244290
Brushholder Assembly, Generator w/Leads
1
218468
Belt, Alternator (Kubota)
1
233482
Kit, Fuel Sedimenter (Kubota)
1
253901
Kit, Filter (Kubota) (Includes)
1
196428
—Filter, Oil
1
207715
—Filter, Fuel Spin-on
1
197676
—Element, Air Cleaner
1
217686
Belt, Alternator (CAT)
1
274427
Kit, Filter CAT (C1.5) Perkins (403-15)
1
202166
—Filter, Oil (CAT)
1
273865
—Filter, Fuel In-line 5/16x5/16 Mic 25
1
217687
—Filter, Fuel Spin-on (CAT)
1
—Element, Air Cleaner
1
197676
♦197679
Element, Air Cleaner Safety
1
Battery, 12V 570 Crk 100 Rsv Gp 35
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-281496 Page 59
SECTION 10 – ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For Models With CAT Engine
OM-281496 Page 60
281494-B
OM-281496 Page 61
Figure 10-2. Circuit Diagram For Models With Kubota Engine
OM-281496 Page 62
276789-D
OM-281496 Page 63
Figure 10-3. Circuit Diagram For Models With CAT Turbo Engine
OM-281496 Page 64
286423-A
OM-281496 Page 65
1-1. Wetstacking
SECTION 11 – RUN-IN PROCEDURE
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
2
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
1
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.
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 runin.
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.
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-
OM-281496 Page 66
+
3
6
11-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
1
7
4
3
5
+
6
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
OMvoltage 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-281496 Page 67
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 Generator Power Receptacles – Neutral
Bonded To Frame
1
2 3-Prong Plug From Case Grounded
Equipment
OR
3 2-Prong Plug From Double Insulated
Equipment
sure equipment has double insu� Be
lated symbol and/or wording on it.
Do not use 2-prong plug unless
equipment is double insulated.
2
3
12-2. Grounding Generator to Truck or Trailer Frame
1-1. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
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.
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCIprotected extension cord. Do not
use GFCI receptacles to power life
support equipment.
OM-281496 Page 68
1 Equipment Grounding
Front Panel)
Terminal
(On
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG
or larger insulated copper wire.
bond
� Electrically
vehicle frame
contact.
generator frame to
by metal-to-metal
12-3. Grounding When Supplying Building Systems
1 Equipment Grounding Terminal
1
2
GND/PE
2 Grounding Cable
Use #8 AWG or larger insulated copper wire.
3 Ground Device
ground device as stated in electri� Use
cal codes.
2
Ground generator to system earth
ground if supplying power to a
premises (home, shop, farm) wiring system.
3
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding
Generators.
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.
3
2
1
VOLTS 115
AMPS 4.5
Hz
50/60
2 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).
3 Rating Data
3
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.
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.
OM-281496 Page 69
OM-4419 Page 1
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
800
300
1/6 HP
1225
500
1/4 HP
1600
600
1/3 HP
2100
700
1/2 HP
3175
875
720
1/3 HP
2020
1/2 HP
3075
975
3/4 HP
4500
1400
1 HP
6100
1600
1-1/2 HP
8200
2200
2 HP
10,550
2850
3 HP
15,900
3900
5 HP
23,300
6800
1-1/2 HP
8100
2000
5 HP
23,300
6000
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
1/8 HP
1000
400
1/6 HP
1400
550
1/4 HP
1850
650
1/3 HP
2400
800
1/2 HP
3500
1100
12-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Rating
Stock Tank De-Icer
Starting Watts
Running Watts
1000
1000
Grain Cleaner
1/4 HP
1650
650
Portable Conveyor
1/2 HP
3400
1000
Grain Elevator
3/4 HP
4400
1400
2900
1100
2 HP
10,500
2800
1/3 HP
1720
720
1/2 HP
2575
975
3/4 HP
4500
1400
Milk Cooler
Milker (Vacuum Pump)
Farm Duty Motors Std. (e.g. Conveyors, Feed Augers, Air
Compressors)
1 HP
6100
1600
1-1/2 HP
8200
2200
2 HP
10,550
2850
3 HP
15,900
3900
5 HP
23,300
6800
1-1/2 HP
8100
2000
5 HP
23,300
6000
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
3-1/2 cu. ft. Mixer
1/2 HP
3300
1000
High Pressure 1.8 Gal/Min
500 PSI
3150
950
Washer 2 Gal/Min
550 PSI
4500
1400
700 PSI
6100
1600
Farm Duty Motors High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk
Feeders)
OM-281496 Page 70
Farm/Home Equipment
Rating
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Starting Watts
Running Watts
3100
800
1/3 HP
2150
750
1/2 HP
3100
1000
1/3 HP
2100
800
1/2 HP
3200
1050
12-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment
Hand Drill
Circular Saw
Rating
Starting Watts
Running Watts
1/4 in.
350
350
3/8 in.
400
400
1/2 in.
600
600
6-1/2 in.
500
500
7-1/4 in.
900
900
8-1/4 in.
1400
1400
9 in.
4500
1500
10 in.
6300
1800
Band Saw
14 in.
2500
1100
Bench Grinder
6 in.
1720
720
1400
Table Saw
8 in.
3900
10 in.
5200
1600
1/2 HP
3000
1000
1 HP
6000
1500
1-1/2 HP
8200
2200
2 HP
10,500
2800
Electric Chain Saw
1-1/2 HP, 12 in.
1100
1100
2 HP, 14 in.
1100
1100
Electric Trimmer
Standard 9 in.
350
350
Heavy Duty 12 in.
500
500
1/3 HP
2100
700
18 in.
400
400
Air Compressor
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
HID
125
100
Metal Halide
313
250
Mercury
1000
Sodium
1400
Vapor
1250
1000
Submersible Pump
400 GPH
600
200
Centrifugal Pump
900 GPH
900
500
3/4 HP, 16 in.
4500
1400
1 HP, 20 in.
6100
1600
1/2 HP
3150
950
3/4 HP
4500
1400
1 HP
6100
1600
1/4 HP
1900
700
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
1.7 HP
900
900
2-1/2 HP
1300
1300
OM-281496 Page 71
12-8. Power Required To Start Motor
1 Motor Start Code
2 Running Amperage
3 Motor HP
4
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
3
4 Motor Voltage
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.
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
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.
1
2 5 Second Rule
2
OM-281496 Page 72
If motor does not start within 5 seconds, turn
off power to prevent motor damage. Motor
requires more power than generator can
supply.
12-10. Typical Connections To Standby Power
1. Utility Electrical
Service
2. Transfer Switch
3. Fused Disconnect
Switch (If Required)
4. Welder/Generator
Output
5. Essential Loads
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.
Do not connect to any electrical distribution system normally supplied
by utility power unless a proper
transfer switch and grounding procedure are employed.
equipment is re� Customer-supplied
quired if generator will supply standby
power during emergencies or power
outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
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 (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-supplied) 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-281496 Page 73
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
A. 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
20
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)
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.
B. 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
20
4 (25)
6 (16)
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)
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)
75 (23)
40
9600
225 (69)
125 (38)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop.
OM-281496 Page 74
Notes
Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK 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.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Serial/Style Number
(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
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and
Parts)
Circuit Diagrams
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
© Miller Electric Mfg. LLC 2019-10
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
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