Miller BIG BLUE 800 DUO AIR PAK User manual

Miller BIG BLUE 800 DUO AIR PAK User manual
OM-259 705K
2015−04
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welder/Generator And
Air Compressor
Big Blue 800
Duo Air Pak
)
)
File: Engine Drive
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
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 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. AC Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Using The Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . .
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . .
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . .
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . .
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . .
5-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Connecting To Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Engine Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
6-5. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Low Open-Circuit Voltage (VRD) Switch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Engine Block Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Optional Air Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. North American Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13. Removing Optional Air Dryer For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − ENGINE INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − AIR COMPRESSOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. . .
SECTION 16 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2013−09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
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!
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).
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment. Do not
test or reset GFCI receptacles at idle speed/low voltage or the
GFCI will be damaged and not provide protection from electric
shock caused by a ground fault.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
OM-259 705 Page 1
FLYING METAL or DIRT can injure
eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND
hazardous.
GASES
can
be
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
OM-259 705 Page 2
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 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 may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
heating operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-259 705 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-259 705 Page 4
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
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.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-259 705 Page 5
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may 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-259 705 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
fre_rom_2013−09
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
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 se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
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.
OM-259 705 Page 7
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire. Ne pas tester ni réarmer les prises femelles avec
différentiel au régime de ralenti/en basse tension: cela endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle
de protection contre une électrocution causée par un défaut de
masse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
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 auxquels est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
OM-259 705 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs 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.
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.
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.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Respecter les consignes du fabricant de la batterie pour travailler
sur une batterie ou à proximité.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, 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.
OM-259 705 Page 9
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.
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.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes
industrielles et aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident matériel
ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air comprimé.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
OM-259 705 Page 10
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.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
comprimé, les branchements et les flexibles en recherchant tout
signe de détérioration, de fuite et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des
gants de soudage et des vêtements épais
pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utiliser un équipement de levage de capacité suffisante pour
lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
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.
OM-259 705 Page 11
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.
Respecter les consignes du fabricant de la batterie pour
travailler sur une batterie ou à proximité.
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge,
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les
accessoires sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en
l’absence d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou
un couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position
d’arrêt avant de brancher la batterie. Veiller à ce que les pinces
de charge ne se touchent pas.
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’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
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.
Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
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.
OM-259 705 Page 12
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Des mesures de protection pour les
porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-259 705 Page 13
Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
OM-259 705 Page 14
Complete Parts List available at www.MillerWelds.com
Do not work on unit if engine is running. Stop engine first.
Safe21 2012−05
Do not smoke while fueling or if near fuel.
Safe22 2012−05
Stop engine before fueling.
Safe23 2012−05
Do not fuel a hot engine.
Safe24 2012−05
Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).
Safe25 2012−05
Do not spray water on electrical parts, including Engine Control Unit (ECU).
Safe 118 2014−10
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2015−02
Hot muffler and exhaust pipe can cause severe burns.
Safe90 2012−07
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
Safe91 2012−07
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-259 705 Page 15
Complete Parts List available at www.MillerWelds.com
Engine fuel plus flames or sparks can cause fire.
=
Safe45 2012−05
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Safe46 2012−05
Read Owner’s Manual. Read labels on unit.
Safe47 2012−05
<12.4 V
Read Owner’s Manual for battery maintenance information.
/
+
−
Safe117 2014−06
+ −
0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.
Safe54 2012−05
50 h std
After the first 50 hours of operation, change the engine oil and filter.
Safe55 2012−05
Never use generator inside a home or garage, even if doors and windows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
3-2. Miscellaneous Symbols And Definitions
Some symbols are found only on CE products.
A
V
Hz
OM-259 705 Page 16
Amperage
Clock, Time
Switch
Direct Current
(DC)
Voltage
Read Operator’s
Manual
Alternating
Current (AC)
Hertz
Negative
Protective Earth
(Ground)
Seconds
Positive
Single Phase
Complete Parts List available at www.MillerWelds.com
Three Phase
s
Engine
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Engine
Engine RPM
Off
Engine Stop
On
Slow
Increase/Decreas
e of Quantity
(Rotating)
Fast
Remote
Engine Belt
Do Not Switch
While Welding
Air Compressor
Welding (General)
Call for
Maintenance
Shielded Metal
Arc Welding
(SMAW)
Check
Injectors/Pump
Flux Cored Arc
Welding (FCAW)
Check Valve
Clearance
I
I2
n
n0
n1
X
h
P1max
Current
Rated Welding
Current
Rated Load
Speed
Rated No−Load
Speed
Rated Idle Speed
Duty Cycle
Hours
Maximum Power
Consumption
Engine−Driven
3−Phase
Alternator with
Rectifier
Circuit Breaker
Supplementary
Protector
Output
Gas Metal Arc
Welding (GMAW)
Certified/Trained
Mechanic
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Previous
Spark Arrestor
Air Cleaner
Lift Arc TIG
Next
Air Temperature
Engine Oil
Engine
Temperature
Menu
Fuel
Filter
Cancel Function
Engine Coolant
Increase
View
Rated No−Load
Voltage (OCV)
Enter
Conventional
Load Voltage
Diagnostics
Battery (Engine)
Engine
U0
U2
OM-259 705 Page 17
Complete Parts List available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the right side. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Weld, Power, And Engine Specifications
Rated Output
Welding
Dual Operator
Mode
(Each Side)
CC/DC
CV/DC
Stick: 400A, 36
VDC, 100% Duty
Cycle
Rated Output
Single Operator
Maximum
Open-Circuit
Voltage
(Nominal)
Stick: 800A, 38
VDC, 100% Duty
Cycle
TIG: 400A, 26
VDC, 100% Duty
Cycle
TIG: 800A, 38 VDC,
100% Duty Cycle
400A, 34 VDC,
100% Duty Cycle
800A, 38 VDC,
100% Duty Cycle
95*
95
Engine
Fuel Tank
Capacity
Deutz TD2.9L4
Liquid-Cooled,
Four-Cylinder,
Turbo-Charged
65.7 HP Diesel Engine
Tier 4 Final Compliant
25 gal
(95 L)
Generator Power Rating
Independent of Weld Output
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC, 50/60 Hz
3-Phase Generator
(In Addition To Standard
4 kVA/kW Generator Power)
Single-Phase/
Three-Phase,12/20 kVA/kW,
50/48 A, 120/240 VAC,
50/60 Hz
* With Low OCV Voltage Reducing Device (VRD) switch enabled, open−circuit voltage is 13 to 15 volts DC until arc initiation for Stick Welding.
4-3. Air Compressor Specifications
Compressor Model And
Type
Air Output At Effective Working
Pressure
Factory Pressure Setting
Safety Relief
Valve Rating
Ingersoll Rand CE55 G
Rotary Screw
60 scfm (1.7 m3 min−1),
100 psi (690 kPa),
100% Duty Cycle
125 psi (862 kPa)
150 psi (1034 kPa)
4-4. Environmental Specifications
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.
Notes
OM-259 705 Page 18
Operating Temperature Range
−40 to 104°F (−40 to +40°C)
IP23S 2014−06
Complete Parts List available at www.MillerWelds.com
4-5. Dimensions, Weights, And Operating Angles
Dimensions
Height
Width
*
53.75 in. (1365 mm)
(to top of exhaust)
G
28-1/2 in. (724 mm)
(mtg. brackets turned in)
30-3/4 in. (781 mm)
(mtg. brackets turned out)
Depth
69.5 in. (1765 mm)
A
69.5 in. (1765 mm)
B*
57.9 in. (1470 mm)
C*
46.375 in. (1178 mm)
D*
11.5625 in. (294 mm)
E
27-1/2 in. (699 mm)
F
1 in. (25 mm)
G
29-13/16 in. (757 mm)
H
9/16 in. (14 mm) Dia.
4 Holes
With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
!
Do not exceed tilt angles or engine could
be damaged or unit could tip.
!
Do not move or operate unit where it could
tip.
A
B
C
30°
30°
H
20°
20°
D
F
Weight
E
No fuel: 2095 lb (950 kg)
W/fuel: 2275 lb (1032 kg)
907 535−1
802 161-A
Lifting Eye Weight Rating:
2500 lb (1134 kg) Maximum
4-6. Duty Cycle And Overheating
1
1
100% Duty Cycle
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
This unit is rated for welding at
Continuous Welding
400 amperes continuously in
dual operator mode or 800 amperes continuously in single
operator mode.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Notes
OM-259 705 Page 19
Complete Parts List available at www.MillerWelds.com
4-7. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
DC VOLTS
80
Parallel Mode
60
Dual Operator
40
20
0
0
100
200
300
400
500
600
700
800
DC AMPERES
B. TIG Mode
100
DC VOLTS
80
Parallel Mode
60
40
Dual Operator
20
0
0
100
200
300
400
500
600
700
800
900
DC AMPERES
C. MIG Mode
DC VOLTS
50
30
10
0
0
−10
OM-259 705 Page 20
100
200
300
400
500
DC AMPERES
600
700
800
259 678-A
Complete Parts List available at www.MillerWelds.com
4-8. AC Generator Power Curves
The AC power curve shows the
generator power in amperes.
A. Single Phase 4 kW
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
AC VOLTS
B. Single Phase 12 kW
140
280
135
270
130
260
125
250
120
240
115
230
110
220
105
210
100
200
95
190
90
180
0
10
20
30
40
50
60
70
80
90
100
AC AMPERES
C. Three Phase 20 kW
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
50
60
253 021-A / 254 115-A / 254 114-A
OM-259 705 Page 21
Complete Parts List available at www.MillerWelds.com
4-9. Fuel Consumption
US Gal./Hr.
The curve shows typical fuel use
under weld or power loads.
4.50
4.25
4.00
3.75
With Air Output
3.50
No Air Output
3.25
3.00
2.75
2.50
2.25
2.00
Dual Weld Mode
1.75
1.50
1.25
1.00
0.75
IDLE
0.50
0.25
0.00
0
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
DC WELD AMPERES AT 100% DUTY CYCLE
259 680-A
Notes
OM-259 705 Page 22
Complete Parts List available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welder/Generator
Airflow Clearance
18 in.
(460 mm)
Movement
18 in.
(460 mm)
18 in.
(460 mm)
OR
OR
18 in.
(460 mm)
18 in.
(460 mm)
Location/Mounting
2
Welding
Unit In
Place
Bolting
Unit In
2 Place
3
4
OR
OR
Tools Needed:
1
1
9/16 in.
Go
to MillerWelds.com for more
information on truck installations.
Movement
!
Do not move or operate unit where
it could tip.
See Section 4-5 for lifting eye rating.
Airflow Clearance
NOTICE − Do not install unit where air flow
is restricted or engine may overheat.
Location/Mounting
!
Always securely fasten welder/generator onto transport vehicle or
trailer and comply with all DOT and
other applicable codes.
install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
!
Do not weld on base. Welding on
base can cause fuel tank fire or explosion. Weld only on the four
mounting brackets or bolt unit
down.
NOTICE − Do not mount unit by supporting
the base only at the four mounting brackets. Use cross-supports to adequately
support unit and prevent damage to base.
1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use cross-supports to support base. Secure unit with
mounting brackets.
3 1/2 in Bolt And Washer (Minimum −
Not Supplied)
4 3/8-16 x 1 in. Screws (Supplied)
To Bolt Unit In Place:
Remove hardware securing the four
mounting brackets to the base. Reverse
brackets and reattach to base with original
hardware.
Mount unit to truck or trailer with 1/2 in. (12
mm) or larger hardware (not supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at the four
mounting brackets.
OM-259 705 Page 23
Complete Parts List available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
rot_grnd2 2014−11 − 800 652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the
welder/generator from the vehicle
!
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
1
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
2
3
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-3. Installing Exhaust Pipe
!
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in.
OM-259 705 Page 24
Ref. 907 535−1 / 907 535−3 / Exhaust3
Complete Parts List available at www.MillerWelds.com
5-4. Connecting The Battery
+
−
Tools Needed:
1/2 in.
NOTICE − Lead acid batteries discharge
when stored in any temperature. Units that
are stored should have the battery
recharged every three months and before
being put into service. To preserve optimum battery performance and life,
recharge battery in storage when the
open−circuit voltage drops to 12.4 volts
DC when measured across the battery
terminals.
! Connect negative (−) cable last.
NOTICE − Wait two minutes after engine
shutdown before disconnecting battery or
engine controller may be damaged.
Conn_batt1 2014−06 802 168-E / S-0756-C
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.
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.
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 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. Using The Battery Disconnect Switch
!
Stop engine.
1
Battery Disconnect Switch
The battery disconnect switch disconnects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On position. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.
1
907 535−2
OM-259 705 Page 25
Complete Parts List available at www.MillerWelds.com
5-6. Engine Prestart Checks
NOTICE − Follow run-in procedure in
engine manual. If unburned fuel and oil
collect in exhaust pipe, see Section 14.
Full
Coolant
Overflow
Tank
Full
Diesel
Full
Check all engine fluids daily.
Automatic warning and shutdown indi-
cators are displayed on the Engine Display. See Section 13 for engine display
information.
Engine must be cold and on a level surface.
Automatic shutdown system stops engine if
oil pressure is too low or engine temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
NOTICE − Diesel engines in Miller equipment are meant to operate optimally at modOM-259 705 Page 26
erate to rated load. Using light or no load for
extended periods of time may cause wetstacking or engine damage.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe, see Section 14.
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Add fresh diesel fuel before starting (see
engine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
Engine stops if fuel level is low.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see engine maintenance label).
Coolant
907 535−1 / 907 535−2
Check coolant level in coolant overflow
tank. Coolant should touch bottom of neck
pipe.
To improve cold weather starting:
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 engine maintenance label or engine manual).
Complete Parts List available at www.MillerWelds.com
5-7. Connecting To Weld Output Terminals
Tools Needed:
1
3
4
5
Stop engine.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
Do not place anything between weld
3/4 in.
6
!
cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
2
1
Correct Weld Cable Connection
2
Incorrect Weld Cable Connection
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
803 778-B
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-259 705 Page 27
Complete Parts List available at www.MillerWelds.com
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
1
1
2
258 836
!
Stop engine.
NOTICE − Do not exceed machine duty
cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
See Section 5-15 for proper cable size.
OM-259 705 Page 28
1
Electrode Holder Cables
2
Work Cables
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and electrode holder cables to Positive (+) terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
Positive (+) terminals and electrode holder
cables to Negative (−) terminals.
Be
sure Process Selector switches
are set correctly. See Section 6-4.
Complete Parts List available at www.MillerWelds.com
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
1
2
1
3
258 836
!
!
Stop engine.
Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connections must be of the same polarity.
NOTICE − For common work connection,
work cable must be able to carry combined
weld output of both modules (see Section
5-15 for proper cable size).
NOTICE − Do not exceed machine duty
cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
1
Electrode Holder Cables
2
Work Jumper Cable
3
Common Work Cable
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect common
work cable and work jumper cable to Welder B (right) Negative (−) terminal. Connect
other end of work jumper cable to Welder A
(left) Negative (−) terminal.
Connect electrode holder cables to Positive
(+) terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect common work
cable and work jumper cable to Welder B
(right) Positive (+) terminal. Connect other
end of work jumper cable to Welder A (left)
Positive (+) terminal.
Connect electrode holder cables to Negative (−) terminals.
Be sure Process Selector switches
are
set correctly. See Section 6-4.
OM-259 705 Page 29
Complete Parts List available at www.MillerWelds.com
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
2
1
1
2
258 836
!
Stop engine.
NOTICE − Do not exceed machine duty
cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
See Section 5-15 for proper cable size.
OM-259 705 Page 30
1
Wire Feeder Cables
2
Work Cables
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire
feeder cables to Positive (+) terminals.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work
cables to Positive (+) terminals and wire
feeder cables to Negative (−) terminals.
Be sure Process Selector
switches are
set correctly. See Section 6-4.
Complete Parts List available at www.MillerWelds.com
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
1
1
2
3
258 836
!
Stop engine.
!
Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connections must be of the same polarity.
NOTICE − For common work connection,
work cable must be able to carry combined
weld output of both modules (see Section
5-15 for proper cable size).
NOTICE − Do not exceed machine duty
cycle.
For common work connection, work
cable must be able to carry combined
weld output of both CC weld output terminals (see Section 5-15 for proper
cable size).
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
1
Wire Feeder Cables
2
Work Jumper Cable
3
Common Work Cable
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect com-
mon work cable and work jumper cable to
Welder B (right) Negative (−) terminal.
Connect other end of work jumper cable to
Welder A (left) Negative (−) terminal.
Connect wire feeder cables to Positive (+)
terminals.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect common
work cable and work jumper cable to Welder B (right) Positive (+) terminal. Connect
other end of work jumper cable to Welder
A (left) Positive (+) terminal.
Connect wire feeder cables to Negative (−)
terminals.
Be
sure Process Selector switches
are set correctly. See Section 6-4.
OM-259 705 Page 31
Complete Parts List available at www.MillerWelds.com
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
1
3
2
3
258 836
!
Stop engine.
NOTICE − Do not exceed machine duty
cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
See Section 5-15 for proper cable size.
1
Electrode Holder Cable
2
Wire Feeder Cable
3
Work Cables
OM-259 705 Page 32
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and electrode holder cable to Positive (+) terminal.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and wire
feeder cable to Positive (+) terminal.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cable to
Positive (+) terminal and electrode holder
cable to Negative (−) terminal.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work
cable to Positive (+) terminal and wire feeder cable to Negative (−) terminal.
Be
Be
sure Process Selector switches
are set correctly. See Section 6-4.
sure Process Selector switches
are set correctly. See Section 6-4.
Complete Parts List available at www.MillerWelds.com
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
Welder B (Right) Side
3
2
1
4
Ref. 251 340-A / Ref. 802 292-A
!
Stop engine.
5-15 for proper cable size).
!
Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − Do not exceed machine duty
cycle.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connections must be of the same polarity.
NOTICE − For common work connection,
work cable must be able to carry combined
weld output of both modules (see Section
Use Dual Operator mode for CC and
CV welding (see Section 6-2).
1
Electrode Holder Cable
2
Wire Feeder Cable
3
Work Jumper Cable
4
Common Work Cable
For Direct Current Electrode Positive
(DCEP), connect common work cable and
work jumper cable to Welder B (right) Negative (−) terminal. Connect other end of
work jumper cable to Welder A (left) Negative (−) terminal.
Connect electrode holder cable to one Positive (+) terminal.
Connect wire feeder cable to remaining
Positive(+) terminal.
Be sure Process Selector switches are
set correctly. See Section 6-4.
For Direct Current Electrode Negative
(DCEN), connect common work cable and
work jumper cable to Welder B (right) Positive (+) terminal. Connect other end of work
jumper cable to Welder A (left) Positive (+)
terminal.
Connect electrode holder cable to one
Negative (−) terminal, and wire feeder
cable to remaining Negative (−) terminal.
Be sure Process Selector switches are
set correctly. See Section 6-4.
OM-259 705 Page 33
Complete Parts List available at www.MillerWelds.com
5-14. Making Single Operator CC Weld Connections
Direct
Current Electrode Positive
(DCEP) connections are shown.
Welder B (right) Terminals
Inactive In Single Operator Mode
Welder A (Left) Side
Tools Needed:
3/4 in.
1
2
258 836
!
Stop engine.
Use Single Operator mode for CC weld-
NOTICE − Do not exceed machine duty
cycle.
ing only. Welder B weld output terminals are disabled in Single Operator
mode. (see Section 6-2).
Welder B (right) weld output terminals
See Section 5-15 for proper cable size.
are disabled in Single Operator mode.
Connect only to Welder A (left) terminals for Single Operator mode operation.
OM-259 705 Page 34
1
Electrode Holder Cable
2
Work Cable
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cable
to Negative (−) terminal and electrode holder cable to Positive (+) terminal.
For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to Positive (+) terminal and electrode holder cable
to Negative (−) receptacle.
Be sure Process Selector switch is set
correctly. See Section 6-4.
Complete Parts List available at www.MillerWelds.com
5-15. Weld Output Terminals And 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
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
250
2 (35)
300
Welding
Amperes
Weld Output
Terminals
!
!
Turn off power before connecting to
weld output terminals.
Do not use worn,
damaged,
undersized, or repaired
cables.
* This
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
10 − 100% Duty Cycle
AWG (mm2)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
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)
600
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
3x4/0
(3x120)
3x4/0
(3x120)
700
4/0 (120)
2x2/0 (2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
3x4/0
(3x120)
3x4/0
(3x120)
4x4/0
(4x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x4/0
(3x120)
3x4/0
(3x120)
4x4/0
(4x120)
4x4/0
(4x120)
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, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-K 2013−09
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-259 705 Page 35
Complete Parts List available at www.MillerWelds.com
5-16. Connecting To Remote 14 Receptacle
Socket*
Socket Information
Not all models have contactor control. See description of front panel controls and
circuit diagram.
A
24 volts AC. Protected by supplementary protector.
B
Contact closure to A completes 24 volt AC contactor
control circuit.
C
Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 volt AC circuit.
24 VOLTS AC
*The remaining sockets
are not used.
REMOTE
OUTPUT
CONTROL
Accessories depend
on unit capabilities.
OR
Rmt14_1 2010−04
Notes
OM-259 705 Page 36
Complete Parts List available at www.MillerWelds.com
5-17. Connecting To The Air Compressor
!
Stop engine and release air pressure before servicing compressor.
2
Open Position
1
Closed Position
907 535−1
!
Air pressure is present at air shutoff
valve whenever Engine Display on
front panel indicates air pressure.
1
3/4 in. NPT Air Pressure
Fitting
2
Air Shutoff Valve
Connect air hose with 3/4 in. NPT fitting (not
supplied) to air shutoff valve.
Be sure valve is in open position when using air compressor.
The compressor runs and air pressure is
available whenever the engine is running
and the front panel Compressor switch is
moved to the On position (see Section 6-2).
Run engine at weld/power speed for maximum air compressor output. Compressor
output is reduced when engine is running at
idle speed.
The air compressor will not start if still under
pressure. If air compressor is turned off,
wait for air pressure to bleed off (about 20
seconds) before turning air compressor on
again.
Using the air compressor does not sig-
nificantly affect weld or generator power output.
OM-259 705 Page 37
Complete Parts List available at www.MillerWelds.com
SECTION 6 − OPERATING WELDER/GENERATOR
6-1. Front Panel Controls (See Section 6-2)
5
4
3
2
6
7
8
9
11
1
10
12
258 833 / 907 535−1
OM-259 705 Page 38
Complete Parts List available at www.MillerWelds.com
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
1
Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed with no generator power or weld
load, and weld/power speed with load applied.
The air compressor load does not affect engine speed. Run engine at weld/power speed
for maximum air compressor output.
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. If unburned fuel
and oil collect in exhaust pipe, see Section 14.
To Start: see Section 6-3 for engine starting
sequence.
To Stop: turn Engine Control switch to Off
position.
2
Engine Display
See Section 13 for engine display information.
Weld Meters
Weld meters also work in combination to
display troubleshooting help codes (see
Section 8-12).
3
DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
4
DC Voltmeter
Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output volt-
age 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 MIG or FCAW position. Turn V/A control
until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults to preset
voltage.
Weld Controls
5
Arc Control
See Section 6-5 for Arc Control information.
6
Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG or FCAW) position, use control to adjust
voltage. Control limits the remote amperage
in Stick or TIG mode, but has no effect in Wire
modes.
7
If a remote device connected to Remote
Receptacle is faulty or is disconnected
during operation, the meters display Help
25 (see Section 8-12). Clear fault by
stopping and restarting the unit or by turning Process/Contactor switch to another
position.
10 Welder Selector Switch
Use switch to select Dual Operator or Single
Operator welding mode.
Place switch in Welder A/Welder B (dual operator) position for CC and CV output from
Welder A (left) and Welder B (right) weld output terminals. Control the weld output from the
terminals on each side using the weld controls on that same side.
Place switch in Welder A (single operator)
position for weld output from Welder A (left)
weld output terminals only.
Welder B (right) weld output terminals are
disabled in Single Operator mode. Connect only to Welder A (left) terminals for
Single Operator operation.
Process/Contactor Switch
See Section 6-4 for Process/Contactor
switch information.
Compressor Controls
8
11 Air Compressor Switch
24 Volts AC Overload Protection
See Section 8-11 for overload protection information.
9
Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/amperage control to the remote control (see Section 6-9).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage settings.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage.
Use switch to turn air compressor on and off.
Air pressure is present at the compressor air
shutoff valve whenever the compressor is
running. The compressor shuts off when the
engine stops. To use air, the compressor must
be turned on each time the engine is started.
The air compressor will not start if still under
pressure. If air compressor is turned off, wait
for air pressure to bleed off (about 20 seconds) before turning air compressor on again.
12 Air Shutoff Valve
!
Air pressure is present at valve whenever Air Pressure display (part of engine display, see Section 13) indicates
air pressure.
Close valve to stop air flow when connecting
or changing tools or air hoses (see Section
5-17).
OM-259 705 Page 39
Complete Parts List available at www.MillerWelds.com
6-3. Engine Starting Sequence
Wait to Start/Preheating
Service Reminder Remaining
Engine Oil
0
1
Compressor Oil
NOTICE − Do not use ether.
If
engine does not start, let engine
come to a complete stop before attempting restart.
To Start:
1 Wait to Start/Preheating Display
0
Service Reminder Remaining
480
Engine Oil
495
Compressor Oil
The Wait to Start display appears when the
Engine Control switch is placed in the Run
or Run/Idle position. Glow plugs function
automatically according to ambient temperature. The operator needs to pause at
either switch position while the engine controller goes through the preheat sequence.
Once this message clears, the engine can
be started.
Turn Engine Control switch to Start. Release Engine Control switch when engine
starts.
To Stop: turn Engine Control switch to Off
position.
6-4. Process/Contactor Switch
1
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor
switch is in an Electrode Hot
position and the engine is running.
Use switch to select weld process and
weld output on/off control (see table below).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-8).
Ref. 258 833-A
OM-259 705 Page 40
REMOTE ON/OFF REQUIRED
ELECTRODE HOT
Complete Parts List available at www.MillerWelds.com
Switch Setting
Typical Process Applications (DC Only)
Electrode Hot – MIG VS
MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable
back to the welder/generator.
Electrode Hot – FCAW VS
FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not require a control cable back to the welder/generator.
Electrode Hot - Stick
Stick welding with or without a remote amperage control. Strike an arc to start welding.
Electrode Hot – TIG Lift Arc
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.
Remote ON/OFF Required - TIG
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote foot 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 - Stick
Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can
help eliminate accidental arc strikes.
Remote On/Off Required - FCAW
FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a
Spoolmatic 30A with WC 24 control.
Remote On/Off Required - MIG
MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or
use a Spoolmatic 30A with WC 24 control.
Notes
OM-259 705 Page 41
Complete Parts List available at www.MillerWelds.com
6-5. Arc Control
1
Arc Control
Stick
Control adjusts Dig when Stick is selected on mode switch.
1
When control is set toward minimum,
short-circuit amperage at low arc
voltage is the same as normal welding amperage.
When set toward maximum, shortcircuit amperage is increased at low
arc voltage to help prevent the electrode from sticking while welding.
Select setting best suited for application.
FCAW/MIG
Control adjusts inductance when
FCAW or MIG position is selected on
the mode switch. Inductance determines the “wetness” of the weld
puddle. Increasing Arc Control setting decreases inductance, thereby
increasing puddle fluidity (“wetness”). Decreasing Arc Control setting increases inductance, decreasing puddle fluidity.
TIG
When the control is set below 1, Auto
Stop is a variable function of preset
weld amperage. This is used with a
short arc length where flare at arc
shutdown cannot be tolerated.
When the control is set above 1, Auto
Stop voltage threshold is a set value
based on preset-set weld amperage
(I) as follows:
I <= 50 A, V=17
I >50 to <=100 A, V=22
I >100 to <=190 A, V=25
I >190A, V=30
This allows for a longer arc length
(such as when “walking the cup”),
where nuisance shutdowns are undesirable.
Control is not functional when TIG
Remote mode is selected.
257 145-A
OM-259 705 Page 42
Complete Parts List available at www.MillerWelds.com
6-6. Low Open-Circuit Voltage (VRD) Switch Mode
1
Voltage Reducing Device
(VRD) Switch
The VRD switch can be set for low
open-circuit voltage operation in
Stick mode. When the unit is configured for low open-circuit voltage
operation only a low sensing
voltage (approximately 15 volts
DC) is present between the electrode and workpiece prior to the
electrode touching the workpiece.
ON
1
Unit is shipped from the factory with
the switch in the On position.
OFF
907 535-2
6-7.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
1
2
3
VRD
Turned
On:
Normal
open-circuit voltage is not present
before electrode touches workpiece;
only a low sensing voltage is present
between electrode and workpiece.
For optimal starting performance, a
good clean contact must be made between the electrode and workpiece.
OM-259 705 Page 43
Complete Parts List available at www.MillerWelds.com
6-8. Lift-Arct TIG With Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc
1
Select Lift-Arc TIG at Process/
Contactor switch.
2
Turn gas on.
1
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Stop to end the arc.
Arc End With Auto-Stop
1
2
3
Arc End With Auto-Stop:
1
2
3
While welding.
Lift torch to start Auto-Stop.
Arc stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
WM Marketing
Notes
OM-259 705 Page 44
Complete Parts List available at www.MillerWelds.com
6-9. Remote Voltage/Amperage Control
1
2
Remote 14 Receptacle
Connect optional remote control to receptacle
(see Section 5-16).
3
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless
of the position of the Process/Contactor
switch.
1
2
3
Voltmeter
Ammeter
CC Welding
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
In Example:
Min = 20 A DC
Max = 205 A DC
85
205
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding
Connect Remote
Control To Remote
Receptacle RC14
Turn Remote Control On. Adjust Optional Remote
Control to 100%
Set TIG or STICK Process
Set V/A Control
To Desired Maximum
Weld Output Using Weld
Meters
Max (205 A DC)
CV Welding
Electrode Hot: Voltmeter toggles between preset and actual output when not welding,
actual voltage while welding.
Remote On/Off Required:
Voltage shown is preset.
28
0
Ammeter Shows Zero
Min (20 A DC)
Adjust Optional Remote
Control to desired
weld output
Adjust Optional Remote
Control to desired
weld output
Connect Remote
Control To Remote
Receptacle RC14
Set WIRE Process
0774 / Ref.246 345-B / Ref. 907 428−1
OM-259 705 Page 45
Complete Parts List available at www.MillerWelds.com
6-10. Engine Block Heater Operation
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.
Coolant Heater
Specifications
Watts
Volts ±10%
530
120
!
Do not run engine while engine block heater is on.
NOTICE −In extremely cold weather, heater should be connected to
120 volts AC receptacle when engine is warm.
!
The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.
1
Coolant heater1 2012−05 907 535 / Ref. 803 145
Notes
OM-259 705 Page 46
Complete Parts List available at www.MillerWelds.com
6-11. Optional Air Dryer Operation
The air dryers blow out (purge) moisture and debris when the air compressor is being used. The air dryer heaters
operate whenever the welder/generator is running.
See the supplied air dryer Owner’s
Manual for air dryer maintenance and
service information.
When battery access is required,
disconnect and remove the air
dryer assembly as described in
Section 8-13.
1
Circuit Breaker CB14
CB14 protects the dryer heaters from
damage due to overload. If CB14
opens, the heaters do not work and the
dryer does not discharge moisture in
cold weather.
Press button to reset circuit breaker
CB14.
2
When a circuit breaker opens, it
usually indicates a more serious
problem exists. Contact a Factory
Authorized Service Agent.
Start engine, and turn on air compressor. Check fittings for air leaks and
tighten fittings if necessary.
2
Timer Control LED
Verify dryer solenoid is functioning by
listening for dryer canisters to purge, or
by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.
1
907 535−2 / 803 228 / 803 229
OM-259 705 Page 47
Complete Parts List available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. North American Auxiliary Power Receptacles
8
6
3
1
7
5
4
2
264 773-A
Single-Phase Generator Power
!
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.
!
Unplug power cord before attempting to service accessories or tools.
1
120 V 20 A AC GFCI
Receptacle GFCI1 or GFCI2
!
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
2
240 V 30 A AC Twistlock
Receptacle RC1 or RC2
Receptacles supply 60 Hz single-phase
power at weld/power speed.
3
Supplementary Protector CB6
4
Supplementary Protector CB7
5
Supplementary Protector CB8
CB6 protects RC1 and RC2, and the gen-
OM-259 705 Page 48
erator winding from overload. If CB6
opens, RC1, RC2, GFCI1 and GFCI2 do
not work. Place switch in On position to reset.
CB7 protects GFCI1 from overload. If CB7
opens, GFCI1 does not work. Press button to reset.
CB8 protects GFCI2 from overload. If CB8
opens, GFCI2 does not work. Press button to reset.
If a supplementary protector contin-
ues to open, contact Factory Authorized Service Agent.
Generator power is not affected by
weld output.
Maximum output is 2.4 kVA/kW from
GFCI1 and 4 kVA/kW from RC1. Maximum output from all receptacles is 4 kVA/
kW.
EXAMPLE: If 13 A is drawn from RC1, only
7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
6
120/240 V 50 A Receptacle RC5
RC5 is connected to the three-phase generator and supplies 60 Hz single-phase
power at weld/power speed. Maximum
output from RC5 is 12 kVA/kW. Power
available at RC5 is reduced when welding.
Three-Phase Generator Power
7
240 V 50 A Three-Phase Receptacle
RC4
RC4 is connected to the three-phase generator and supplies 60 Hz three-phase
power at weld/power speed. Maximum
output from RC4 is 20 kVA/kW. Power
available at RC4 is reduced when welding.
8
Supplementary Protector CB1
Supplementary protector CB1 protects
three-phase
receptacle
RC4,
single-phase receptacle RC5, and the
load wires from overload. If CB1 opens, all
generator output stops and the receptacles do not work.
Complete Parts List available at www.MillerWelds.com
7-2. GFCI Receptacle Information, Resetting And Testing
1
2
3
4
!
Test and reset GFCI only at Run speed.
RotGFCI1 2014−09
!
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.
1
120 V 20 A AC GFCI Receptacle
2
GFCI Receptacle Test Button
3
GFCI Receptacle Reset Button
4
GFCI Indicator Light (LED)
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
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.
Resetting/Testing GFCI Receptacle
!
Test GFCI monthly. See Testing
GFCI Receptacle.
!
Do not test or reset GFCI receptacles
at idle speed/low voltage or the GFCI
will be damaged and not provide
protection from electric shock
caused by a ground fault.
!
!
If LED blinks, stop using GFCI receptacle and have it replaced by a
Factory Authorized Service Agent.
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 and operate at Run (weld/
power) speed. 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
GFCI testing must be done with engine
running at Run (weld/power) speed.
Start engine and operate at Run (weld/
power) speed.
Press the GFCI Test button. The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur:
GFCI does not trip when tested
LED blinks
GFCI does not reset.
OM-259 705 Page 49
Complete Parts List available at www.MillerWelds.com
SECTION 8 − MAINTENANCE
8-1. Maintenance Label
OM-259 705 Page 50
Complete Parts List available at www.MillerWelds.com
DEUTZ Service: http://www.deutzamericas.com
To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer: http://www.deutzamericas.com/deutznew/distributors/index.htm.They are staffed with highly qualified parts, service and engine specialists to handle your different needs.
The DEUTZ Service Desk enhances this support and can be contacted by completing and submitting the Service Support Form. Customer in the
US and CANADA can also contact the service desk by calling our toll free number, 1-800-241-9886.
Our normal hours of operation are from 8:00 AM to 6:00 PM Monday through Friday EST. You may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us, please have available or provide specific engine information (serial number, model number etc.) as shown
on the Service Support Form.
8-2. Cleaning Unit
Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust.
NOTICE − Use of a power washer is acceptable; however, cover or avoid electrical parts and the Engine Control Unit (ECU) located on the lower left
side of the center upright.
8-3. Routine Maintenance
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
8
Hours
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Section 5-6
See
engine
manual for fuel
specifications.
FUEL
WATER
Primary Fuel Filter
Stop engine before maintaining.
See
Fuel Level
Oil Level
Oil, Fuel Spills
= Clean unit exterior, including stainless steel, frequently to prevent rust and
corrosion.
Coolant Level
Every
100
Hours
Section 8-6
Battery Terminals
Every
250
Hours
Air Cleaner Hoses
Air Cleaner Element
Weld Terminals
Engine
Manual
1/2 in.
(13 mm)
Unreadable Labels
Every
500
Hours
Fan Belt Tension
Cooling System
Spark Arrestor
NOTICE − Change engine
oil and filter after initial 50
to 75 hours of use.
See engine manual for oil
specifications.
Oil
Oil Filter
Every
1000
Hours
Section
8-10, and
Engine
Manual
Fuel Filters
Weld Cables
FUEL
OR
SLUDGE
Slip Rings*
Brushes*
Inside Unit
Valve Clearance*
Section
8-4, 8-10,
and Engine
Manual
Drain Sludge
NOTICE − Use extended
life coolant only.
See engine manual for
coolant specifications.
Every
2000
Hours
Coolant
Every
3000
Hours
Every
6000
Hours or
5 Years
Injectors*
Engine Timing Belt
OM-259 705 Page 51
Complete Parts List available at www.MillerWelds.com
8-4. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush holder cap. Remove brushes.
New Length:
1-1/4 in. (32 mm)
Minimum Length:
5/8 in. (16 mm)
Replace brushes if damaged or if brush
material is at or near minimum length.
1
Replace
Damaged Brushes
GenBrush1 2014−10 / Ref 190 823
8-5. Battery Replacement
Tools Needed:
!
Stop engine.
1
Battery Locator Bracket
Mounting Holes
Access battery as shown in Section
5-4. Disconnect battery.
Larger Battery
Remove J-bolts securing battery
and remove battery.
Battery locator brackets can be
moved to accommodate batteries
of different physical sizes.
Install and secure replacement battery.
!
Connect negative (−) battery
cable last.
Smaller Battery
1
255 858
OM-259 705 Page 52
Complete Parts List available at www.MillerWelds.com
8-6. Servicing Air Cleaner
2
1
!
Stop engine.
!
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.
Remove compressor air cleaner cov-
er and element to access engine air
cleaner.
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
3
4
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.
6
5
1
2
Engine Air Cleaner
Compressor Air Cleaner
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Optional
7
3
Housing
4
Safety Element (Optional)
5
Primary Element
6
Cover
7
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 cover.
Keep nozzle
2 in. (51 mm)
from element.
!
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Blow
Inspect
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).
aircleaner1 9/02− ST-153 929-B / ST-153 585 / Ref. S-0698-B
8-7. 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.
8-8. Engine Speed Adjustment
Engine functions are controlled by the engine ECU. Tampering with the engine ECU may void engine warranty. Contact engine Factory Authorized
Service Agent for engine adjustments.
OM-259 705 Page 53
Complete Parts List available at www.MillerWelds.com
8-9. Oil Specifications
Synthetic Oil Viscosity Chart
For any normal oil change interval, any en-
gine oil with a CJ-4 and low ash rating may
be used. After the initial run-in period, synthetic oil may be used to replace oil
shipped in the engine.
Synthetic lubricating oils have a better temperature and oxidation stability, better soot
dispersal properties, and a relatively low
cold viscosity making them suitable for use
in arctic temperatures.
Use table to select appropriate product.
All products listed comply with DQC IV-10LA and have Base Number (TBN) ≥9 mg KOH/g
Manufacturer
Product Name
SAE Class/Weight
Addinol
Addinol Extra Truck MD 1049 LE
10W-40
Aral AG
Aral Mega Turboral LA 10W-40
10W-40
BP Plc.
BP Vanellus Max Eco 10W-40
10W-40
Castrol Limited
Castrol Enduron Low SAPS 10W-40
10W-40
Chevron Global Lubricants
Chevron Delo 400 LE Synthetic 5W-30
5W-30
Texaco Ursa Ultra XLE 5W-30
5W-30
ExxonMobil Corp.
Mobil Delvac XHP LE 10W-40
10W-40
Fuchs Petrolub AG
Titan Cargo Maxx 5W−30
5W-30
Titan Cargo Maxx 10W-40
10W-40
Hessol Lubrication GmbH
Hessol Dimo Extra
10W-40
Lukoil Lubricants
Lukoil Avantgarde Professional LS
5W-30
OMV
OMV Truck Blue ET SAW 10W-40
10W-40
PHI Oil GmbH
Motodor LSP Gold 5W-30
5W-30
Repsol
Repsol Ecotech Premium Low SAPS W-40
10W-40
SRS Schmierstoff Vertrieb GmbH
SRS Cargolub TLS
5W-30
Shell International
Shell Rimula R6 LM
10W-40
Unil Opal
Pallas 900
10W-40
Valvoline
Valvoline ProFleet LS SAE 10W-40
10W-40
For additional DQC IV-10LA oil products, see www.deutz.com/service/operating_liquids_brand_additives/deutz_quality_class.en.html.
OM-259 705 Page 54
Complete Parts List available at www.MillerWelds.com
8-10. Servicing Fuel And Lubrication Systems
Tools Needed:
5
4
3
1
6
2
907 535−2
!
Stop engine and let cool.
formation.
!
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
To replace fuel filters:
1
2
3
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
Turn filter counterclockwise. Remove filter.
4
Primary Fuel Filter
5
Secondary Fuel Filter
6
Fuel Tank Sludge Drain Valve
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 in-
For primary fuel filter, disconnect water sensor connection.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clockwise. For primary fuel filter, reconnect water
sensor. Bleed air from fuel system according to engine manual.
Inspect fuel line, and replace if cracked or
worn.
Close doors.
To reset service reminder intervals shown
on the Engine Display, see Sections 13-12
and 13-13.
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.
!
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining fuel tank.
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.
OM-259 705 Page 55
Complete Parts List available at www.MillerWelds.com
8-11. Engine/Generator Overload Protection
1
8
9
10
2
11
3
4
7
6
5
907 535−2 / 803 229
!
Stop engine.
When a supplementary protector, cir-
cuit breaker or fuse opens, it usually indicates a more serious problem exists.
Contact Factory Authorized Service
Agent.
See Section
9-4 for air compressor
overload protection.
See Section 6-11 for air dryer overload
protection.
1 Supplementary Protector CB9/CB29
CB9 and CB29 protect the 24 volt AC output to remote receptacles. If CB opens,
weld output and 24 volt output to remote receptacle stops.
2 Supplementary Protector CB15
Compressor overload protection, see Section 9-4.
3 Fuse F1
4 Fuse F2
F1 and F2 protect the stator exciter winding
OM-259 705 Page 56
from overload. If F1 opens, weld and generator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.
5 Supplementary Protector CB14
Air dryer overload protection, see Section
6-11.
6 Supplementary Protector CB3
7 Supplementary Protector CB4
CB3 protects the engine weld control circuit. If CB3 opens, weld output stops,
meters will be blank; however, generator
power is still available.
CB4 protects the field flashing circuit. If
CB4 opens, the generator may not excite at
start-up and weld and generator power output may not be available.
8 Supplementary Protector CB2
CB2 protects the engine control circuit. If
CB2 opens, the engine does not crank.
9
Supplementary Protector CB11
CB11 protects the 12 volts DC supply to the
engine ECU. If CB11 opens, the engine will
stop. Since the ECU generates error messages, no error message may appear on
the Engine Display.
10 Supplementary Protector CB12
CB12 protects the fuel pump circuit. If
CB12 opens, the fuel pump does not work
and the unit will stop.
11 VRD Switch
See Section 6-6 for VRD switch information.
12 Circuit Breaker CB10 (Not Shown)
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault is
corrected.
13 Circuit Breaker CB13 (Not Shown)
CB13 protects the glow plug circuit. If
CB13 opens, the glow plug will not operate.
CB13 automatically resets when the fault is
corrected.
Complete Parts List available at www.MillerWelds.com
8-12. Voltmeter/Ammeter Help Displays
1
2
HL.P
20
3
HL.P
21
4
HL.P
22
5
HL.P
25
HL.P
26
Use the Voltmeter/Ammeter help displays
to diagnose and correct fault conditions.
When a help code is displayed normal-
ly weld output has stopped but generator power output may be okay.
To reset help displays, stop
unit and
then restart. See item 4 below to reset
Help 25 display.
1 Help 20 Display
Indicates a failure of meter display module
PC2/PC22, or the wiring between
PC2/PC22 and main control module PC1
(A Side)/PC21 (B Side), or PC1/PC21. If
this display is shown, have Factory Authorized Service Agent check PC1/PC21,
PC2/PC22, and the wiring between them.
2 Help 21 Display
Thermistor TH1 in the IGBT module (each
side) on the heat sink has failed. If this display is shown, have Factory Authorized
Service Agent check TH1 (each side), and
the wiring between TH1 and PC1/PC21.
3 Help 22 Display
Indicates the IBGT module heat sink (each
side) has overheated. If this display is
shown, check generator cooling system
and/or reduce duty cycle. Keep engine access door closed when running to maintain
proper cooling air flow past the heat sinks.
Allow unit to cool before restarting. If problem continues, have Factory Authorized
Service Agent check unit.
4 Help 25 Display
Indicates a remote device connected to
Remote Receptacle RC14 may be faulty.
Help 25 is also displayed whenever a remote device has been connected to RC14
and then disconnected. Clear fault by stopping and restarting the unit or by turning
Process/Contactor switch to another position. If problem continues, have Factory
Authorized Service Agent check the remote device, filter board PC5/PC25, and
main control module PC1/PC21.
5 Help 26 Display
Indicates a fault when attempting to operate the unit in single operator mode (outputs internally paralleled). Help 26 indicates a failure of either side A or side B or
the communications between them which
prevents the unit from being operated in
the single operator mode. Return to dual
operator mode and check for output at both
sides. If output is normal, contact Factory
Authorized Service Agent to check internal
wiring and communications between
sides.
OM-259 705 Page 57
Complete Parts List available at www.MillerWelds.com
8-13. Removing Optional Air Dryer For Service
Follow this procedure whenev-
er the air dryer must be removed to gain access to the
battery.
1
Air Line
2
Timer Control Cable
3
Air Dryer Heater Plug
4
Solenoid LED
Disconnect air line from dryer assembly bottom inlet.
Disconnect heater cable from bottom of air dryer assembly.
Loosen hardware securing battery
access panel to rear panel. Carefully pull access panel/air dryer assembly away from unit rear panel.
Support dryer assembly to relieve
strain on timer control cable.
3
Disconnect battery negative (−)
cable. When service is complete,
reconnect battery negative (−)
cable.
2
Reinstall battery access panel/air
dryer assembly. Reconnect air dryer heater cable.
Reconnect air line to dryer bottom
inlet.
Final-tighten all hardware, and
air line and air dryer fittings.
Start engine, and turn on air compressor. Check fittings for air leaks
and tighten fittings if necessary.
1
Verify dryer solenoid is functioning
by listening for dryer canisters to
purge, or by checking solenoid
LED. LED lights at start-up and every two minutes when the canisters
automatically purge.
4
803 511
OM-259 705 Page 58
Complete Parts List available at www.MillerWelds.com
SECTION 9 − AIR COMPRESSOR MAINTENANCE
9-1. Air Compressor Maintenance Label
The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment.
The compressor will require service more often if used in dirty, humid conditions.
Notes
OM-259 705 Page 59
Complete Parts List available at www.MillerWelds.com
9-2. Routine Air Compressor Maintenance
See Section 8 for engine/generator maintenance information.
!
Recycle air
compressor
fluids.
Stop engine before maintaining.
Service air compressor more often if used in severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Replace
Reference
Every
8
Hours
Section 9-5
Spills
Oil Level
Every
250
Hours
Section 9-3
Unreadable Labels
Worn or Damaged Air/Oil
Hoses
Belt Tension
Air Cleaner Hoses
Air Filter Element
Cooling System
Every
500
Hours
Section 9-5
Oil
Every
1000
Hours
Oil Filter
Section 9-5
Air/Oil Separator
OM-259 705 Page 60
Complete Parts List available at www.MillerWelds.com
9-3. Servicing Compressor Air Cleaner
!
Stop engine.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
damaged element is not covered by the
warranty.
1
1
Compressor Air Cleaner
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional air compressor
protection. Never clean a safety element. Replace the safety element after servicing the primary element
three times.
2
3
4
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
2
Housing
3
Safety Element
4
Primary Element
5
Cover
6
Dust Ejector
To clean air filter:
6
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.
NOTICE − Do not clean housing with air
hose.
Keep nozzle
2 in. (51 mm)
from element.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).
Blow
Inspect
aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B
OM-259 705 Page 61
Complete Parts List available at www.MillerWelds.com
9-4. Compressor Overload Protection
!
Stop engine.
When
a circuit breaker or fuse
opens, it usually indicates a more
serious problem exists. Contact
Factory Authorized Service Agent.
See Section 8-11 for engine/generator overload protection.
1
Circuit Breaker CB15
Circuit breaker CB15 protects the air
compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.
Press button to reset breaker.
1
907 535−2
OM-259 705 Page 62
Complete Parts List available at www.MillerWelds.com
9-5. Servicing Air Compressor
Tools Needed: 7/8, 15/16 in.
Air Compressor Assembly Right Side
7
4
5
6
Too
High
2
Full
3
Full
Too
Low
1
907 535−2 / 2555 862-A
!
Stop engine and let cool. Wait 20 seconds for system pressure to drop before changing oil.
1
Air Compressor Oil Filter
2
Secondary Air Compressor Air/Oil
Separator
3
Air Compressor Oil Drain Hose
w/Removable Cap
4
Air Compressor Oil Fill Cap
5
Air Compressor Oil Level Indicator
6
Air Compressor Primary Air/Oil
Separator Tank
7
Oil Scavenge Tube
To change compressor oil and filter:
The engine oil drain
and compressor oil
drain hoses are located together in the
base. Be sure to select the correct hose
when draining compressor oil.
Be sure o-rings at oil drain and oil fill fit-
tings are in place before reinstalling caps.
Drain compressor oil while compressor is still
warm.
Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Remove cap from oil drain hose and drain oil into
a suitable container. Reinstall oil drain hose
cap. Tighten cap with wrench.
Remove filter by turning filter counterclockwise. Remove filter. Apply thin coat of oil to
gasket on new filter. Install new filter and turn
clockwise until tight.
Add recommended oil until oil level indicator
shows system is full (see compressor maintenance label for oil specifications). Reinstall oil
fill cap. Tighten cap with wrench.
To replace secondary air/oil separator:
Loosen nut securing oil scavenge tube on
separator base. Lift oil scavenge tube from
separator. Turn filter counterclockwise. Remove filter.
Apply thin coat of oil to gasket on new filter.
Install filter and turn clockwise. Reinstall oil
scavenge tube.
Start engine, run air compressor, and check
for oil leaks.
!
Stop engine.
OM-259 705 Page 63
Complete Parts List available at www.MillerWelds.com
9-6. Adjusting Compressor Air Pressure
Check compressor air pressure using
air pressure gauge known to be accurate. If necessary, adjust air pressure
as follows:
Tools Needed:
1
5/16, 3/8 in.
Screw
Loosen jam nut securing screw. Turn
screw clockwise (increase pressure)
or counterclockwise (decrease) until
pressure is 125 psi (862 kPa).
Maximum weld output is reduced
if compressor air pressure is set
above 125 psi (862 kPa).
Tighten nut.
2
Pressure Relief Valve
Pressure relief valve opens and releases pressure at 150 psi (1034
kPa). The pressure relief valve is not
adjustable.
Air Compressor Assembly Left Side
2
1
255 862-A / Ref: 803 228
OM-259 705 Page 64
Complete Parts List available at www.MillerWelds.com
SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12). Also see Engine Information Display
to assist in troubleshooting engine related problems (see Section 13).
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in an Electrode Hot position, or place switch in a Remote On/Off Reokay at AC receptacles.
quired position and connect remote contactor to Remote 14 receptacle (see Sections 5-16).
Reset supplementary protector CB3 (see Section 8-11).
Reset supplementary protector CB9 and/or CB29 (see Section 8-11). Check for faulty remote device
connected to Remote 14 receptacle.
Check and secure connections to Remote 14 receptacle (see Section 5-16).
If VRD switch S5 is On, check voltage feedback wires at output terminals and have Factory Authorized
Service Agent check main control board PC1 or PC21.
Have Factory Authorized Service Agent check filter board PC5 and/or PC25 and connections.
Check fuse F2, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check
brushes and slip rings, weld excitation circuit, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB4 (see Section 8-11).
Check fuses F1 and F2, and replace if open (see Section 8-11). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.
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.
Check position of Voltage/Amperage Adjust control.
Have engine Factory Authorized Service Agent check engine speed.
Have Factory Authorized Service Agent check voltage feedback circuit.
Low weld output.
Check position of Voltage/Amperage Adjust control.
Have engine Factory Authorized Service Agent check engine speed.
Check fuses F1 and F2, and replace if open (see Section8-11). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.
Place VRD switch S5 in Off position and try welding. If machine operates normally, have Factory Authorized Service Agent check S5 and Main Control Board PC1 and PC21.
Low open-circuit voltage.
Have engine Factory Authorized Service Agent check engine speed.
Check position of Process/Contactor switch.
High open-circuit voltage with VRD Have Factory Authorized Service Agent check IGBT Modules PM1, PM2, PM21, and PM22; check and
switch On.
replace Main Control Boards PC1 and PC21.
No remote fine amperage or voltage Check and secure connections to Remote 14 receptacle (see Section 5-16).
control.
OM-259 705 Page 65
Complete Parts List available at www.MillerWelds.com
Trouble
Remedy
No remote fine amperage or voltage Repair or replace remote control device.
control (Continued).
Have Factory Authorized Service Agent check current sensing devices, and connections.
Constant speed wire feeder does not Reset supplementary protector CB9 or CB29 (see Section 8-11).
work.
Check and secure connections to Remote 14 receptacle (see Section 5-16).
Repair or replace wire feeder.
Low CV weld output.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Process/Contactor switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control and field current
regulator board.
With VRD switch S5 On, machine does Have Factory Authorized Service Agent check and replace Main Control Board PC1 or PC21.
not return to low open−circuit voltage at
the end of weld.
B. Standard Generator Power
Trouble
Remedy
No generator power output at AC recept- Reset receptacle supplementary protectors. Reset GFCI receptacle.
acles; weld output okay.
Check fuse F1, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check
integrated rectifiers SR1 and SR2, resistor R3, and capacitor C6.
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-11). Have Factory Authorized Service Agent
check integrated rectifiers SR1 and SR2, capacitor C6, and the rotor.
Reset supplementary protector CB4. Have Factory Authorized Service Agent check integrated rectifier
SR1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC re- Have engine Factory Authorized Service Agent check engine speed.
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power AC re- Have engine Factory Authorized Service Agent check engine speed.
ceptacles.
Check fuse F1, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check
integrated rectifier SR2, resistor R3, and capacitor C6.
Have Factory Authorized Service Agent check brushes and slip rings.
C. Three-Phase Generator Power
Trouble
No or low output at three-phase generator/receptacle RC5.
Remedy
Reset supplementary protector CB1 (see Section 7-1).
Have engine Factory Authorized Service Agent check engine speed.
Have Factory Authorized Service Agent check brushes and slip rings.
High output at three-phase generator/
receptacle RC5.
Have engine Factory Authorized Service Agent check engine speed.
Erratic output at three-phase generator/ Have Factory Authorized Service Agent check brushes and slip rings.
receptacle RC5.
OM-259 705 Page 66
Complete Parts List available at www.MillerWelds.com
D. Engine
Trouble
Engine will not crank.
Remedy
Supplementary protector CB2 open. Reset CB2.
Check battery connections and tighten if necessary. Check battery, and replace if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-11).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check control relay CR5 and Engine Control switch S1.
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 CR5. Have engine Factory Authorized
Service Agent check fuel pump and fuel system.
Air in fuel system. See engine manual.
Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch is released.
is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.
Have Factory Authorized Service Agent check control relay CR5.
Engine hard to start in cold weather.
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 maintenance label and engine manual).
Engine suddenly stops.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections8-6 and 8-10).
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 engine Factory Authorized Service Agent check speed control.
Engine does not run at idle speed.
Have Factory Authorized Service Agent check control relays CR3 and CR4/CR24.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 14).
wetstacking occurs.
E. Air Compressor
Trouble
Remedy
Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If
pressure at air shutoff valve.
compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor
on again.
Reset supplementary protector CB15 (see Section 9-4).
Check compressor belt tension. Be sure correct belt is used and is properly installed.
Verify secondary air/oil filter is not plugged. Replace air/oil separator.
Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pressure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.
OM-259 705 Page 67
Complete Parts List available at www.MillerWelds.com
Trouble
Remedy
Air compressor stops after short period Check compressor oil level (see Section 9-5). Automatic shutdown stops compressor if compressor temof operation.
perature is too high.
Clean debris from radiator. Automatic shutdown stops compressor if compressor temperature is too high.
Low air pressure.
Check for leaks in air lines and hoses.
Adjust compressor air pressure (see Section 9-6).
Check air compressor air cleaner (see Section 9-3).
Have Factory Authorized Service Agent check compressor for rated output.
High air pressure.
Adjust compressor air pressure (see Section 9-6).
Be sure control line is connected at regulator valve and inlet valve.
Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195 117).
moisture in compressed air.
Oil in air from compressor.
Check compressor oil level (see Section 9-5). If oil level is too high, system becomes saturated with oil.
Change compressor air/oil separator (see Section 9-5).
Check connections of control lines (see air compressor circuit diagram in Section 12).
Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.
Oil in compressor air cleaner.
Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.
SECTION 11 − PARTS LIST
11-1.
Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 262459 . . Kit, Filters Deutz (2.9l4) Engine (Includes)
. . . . . . . . . . . . . . . . . . . . 192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 255765 . . . . Filter, Fuel Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 255764 . .
Filter, Fuel Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 246991 . . Filter Kit, Ingersoll Rand (Ce55 G1) (Includes)
. . . . . . . . . . . . . . . . . . . . 206745 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206747 . . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 253944 . . Belt, Micro-v 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 925 Crk 195 Rsv Gp 31 Maint Free . . . . . . . . . . . . . . . . .
♦Optional
OM-259 705 Page 68
2
3
1
1
1
1
1
1
1
1
1
1
Notes
OM-259 705 Page 69
SECTION 12 − ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For Welder/Generator − Part 1
OM-259 705 Page 70
258 725-H
OM-259 705 Page 71
Figure 12-2. Circuit Diagram For Welder/Generator − Part 2
OM-259 705 Page 72
258 725-H
OM-259 705 Page 73
SECTION 13 − ENGINE INFORMATION DISPLAY
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
13-1. Display Layout And Controls
1
2
3
4
5
Engine Information Display
Engine Control Switch
Function Buttons
Yellow LED
Red LED
The Engine Information Display
turns on whenever the Engine Control switch is in either Run or Run/
Idle with the engine not running.
1
5
4
2
3
When
starting the engine,
pause Engine Control switch in
Run or Run/Idle position for
several seconds. The engine
controller initiation sequence
must occur. If glow plugs are on
(automatically determined by
ambient temperature), also
wait until the initial Wait to Start
message on the display is
cleared (see Section 13-4).
Function buttons are used to navigate through menus, increment/
decrement, and select (see Section
13-2).
The yellow LED lights as part of sequences used to alert the operator
to errors or conditions that will affect
operation, such as low fuel.
The red LED lights as part of a shutdown sequence, such as when fuel
is too low or oil pressure is too low
to continue operation without damaging the engine.
MurphyDisplay 2014−03 / 258 833-D
13-2. Function Buttons
Function Button
Previous
Next
Menu/Cancel
View
Enter/Diagnostic
6-Up Display
None
None
Menu
Go to 1-Up
Engine Diagnostics
1-Up Display
Previous
Next
Menu
Go to 6-Up
Engine Diagnostics
OM-259 705 Page 74
13-3. RPM Signal Failed Display
1
RPM Signal Failed Display
If the operator places the Engine
Control switch in the Run/Idle or
Run position and does not start the
engine, a timer starts. If this condition exists for 5 minutes or longer,
the RPM signal failed message appears. Place Engine Control switch
in Off position to reset.
1
RPM SIGNAL FAILED
Hide
13-4. Service Reminder Screen
1
2
Wait to Start/Preheating
Service Reminder
Engine Oil
Compressor Oil
Glow plugs turn on automatically as de-
termined by ambient temperature.
Compressor oil information appears
only on models with air compressor.
1 Wait to Start/Preheating Display
The Wait to Start display appears when the
Engine Control switch is in the Run or Run/
Idle position and glow plugs are functioning.
The operator needs to pause at either
Remaining
0
0
Service Reminder
Engine Oil
Compressor Oil
switch position while the engine controller
goes through the preheat sequence. Once
this message clears, the engine can be
started.
2
Service Reminder Display
The Service Reminder display shows servicing intervals in hours counting down
from engine manufacturer recommended
service intervals. This display appears for
Remaining
480
495
a few seconds. It can also be found as a
1-up screen (see Section 13-7).
The 6-Up Display then appears as the default. The engine can be started when the
6-Up Display appears.
If the Enter/Diagnostic function button is
pressed while in this display, the DM2 diagnostic screen appears. (see Section
13-11).
OM-259 705 Page 75
13-5. 6-Up Display
2
1
0.0 H
0 PSI
0.0 H
0 PSI
9
3
0%
32 F
0%
32 F
8
4
0 VDC
0 RPM
7
6
5
1
0 VDC
0 PSI
n/min
6-Up Display With Engine RPM
This is the default screen configuration. If
the operator wants to toggle to the 1-Up
Display, press the View function button.
The Oil Pressure 1-Up Display appears
(see Section 13-6).
2
6-Up Display With Air Compressor
Pressure (Models With Air
Compressor)
The air compressor must be on and air
pressure must be available for this display
to appear.
3 Engine Oil Pressure
4
5
6
7
8
9
Engine Coolant Temperature
Engine RPM
Compressor Air Pressure
Battery Voltage
Fuel Level
Engine Hourmeter
13-6. Getting To 1-Up Display
1
View Function Button
From 6-Up Display, press the
View function button to go to 1-Up
Display.
2
0 PSI
0.0 H
32 F
0%
0 RPM
0 VDC
n/min
45 60
75
30
90
15
105
0
2
1
OM-259 705 Page 76
Oil Pressure
1-Up Oil Pressure Display
To increment to the next display,
press the Next function button. To
return to the 6-Up Display, press
the View function button.
0 PSI
13-7. 1-Up Displays
1
1-Up Machine Hours Display
To increment to the next display,
press the Next function button. To
return to previous display, press
the Previous function button. To
return to the 6-Up Display, press
the View function button.
1
0H
Machine Hours
9
15 18
6
125
100 150
175
75
50
200
25
12
3
0V
0
225
250
Battery Potential
0F
Coolant Temperature
125
100
75
100
50
75
25
50
0
25
0%
0
0%
Percent Load@RPM
Fuel Level
Engine Oil
1000 1500
500
2000
n/min
2500
0 RPM
0H
Service Reminders
Engine Speed
OM-259 705 Page 77
13-8. 1-Up Compressor Displays
1
1
80
120
40
To increment to the next display,
press the Next function button. To
return to previous display, press the
Previous function button. To return
to the 6-Up Display, press the View
function button.
Air Pressure display does not
160
200
appear if the air pressure input
is less than 50 PSI.
0 PSI
Air Pressure
0H
Compressor Oil
Engine Oil
0H
0H
Service Reminders
OM-259 705 Page 78
Air Compressor Pressure
1-Up Display
Compressor Hours
13-9. Fuel Level Warnings
Fuel level warnings are generat-
0 PSI
0.0 H
32 F
0%
0 RPM
0 VDC
1
ed by sensors at the fuel tank. All
engine warnings that are displayed are generated by the engine controller (see Sections
13-10 and 13-11).
1
2
3
6-Up Display
1-Up Fuel Level Display
Low Fuel Warning
The low fuel warning indicator appears and begins to flash when fuel
level reaches 10%. It continues to
flash until fuel level falls to 0%.
4
Yellow LED
The yellow LED begins to flash when
the low fuel warning appears. It continues to flash until 0% is reached.
5
Red LED
The red LED turns on and stays lit
when fuel level reaches 0%. The engine will shut down.
6
No Fuel Display
This display appears at engine shutdown. Turn Engine Control switch to
Off, refuel, and restart.
3
100
2
75
50
25
0
Fuel Level
4
5
6
NO FUEL
Hide
OM-259 705 Page 79
13-10. Warning or Shutdown Display
1
2
Oil Pressure Display
Fault Warning Indicator
The warning symbol appears on the
display when an engine condition
approaches a shutdown condition.
1
45 60
75
30
90
15
105
3
2
0 PSI
3
The 6-up or 1-up screen with fault
indicator is shown briefly and
automatically advances to the
fault display.
Oil Pressure
4
5
6
7
8
7
9
9 Diagnostic Description
10 Occurrence Count
5
0 of
0
SPN:
Fault Display
Level Of Fault
Indicates Number Of Faults
Suspect Parameter Number
Failure Mode Identifier
The SPN and FMI numbers are
generated by the engine controller
according to the J1939 standard.
Typical faults are listed in
Table 13-1.
4
6
Fault Shutdown Indicator
The shutdown symbol appears on
the display when a severe engine
fault can cause shutdown.
Warning
0
For non−critical faults, the number
of occurrences can accumulate
8
FMI
11 Previous Function Button
12 Next Function Button
13 Hide Function Button
0
Dm1. DiagnosticString
Non−critical faults can be hidden.
14 Acknowledge Function Button
OC:
Prev
Next
Hide
0
14
12
13
1 of
1
SPN:
Warning
100 FMI
1
Low oil pressure warning threshold
exceeded
OC:
Prev
Next
Hide
1
Ack
To acknowledge the fault and advance the display to the 1-up or
6-up display, press the Ack function
button and then the Hide function
button.
The condition that caused the
Ack
11
OM-259 705 Page 80
10
warning or shutdown must be
remedied before operation can
continue.
Table 13-1. Fault Descriptions
This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized
Service Agent.
SPN
FMI
Description of Fault
Tier 3 or Tier 4 Interim Engines
100
2
Low oil pressure; warning threshold exceeded
110
2
High coolant temperature; warning threshold exceeded
Tier 4 Final Engines
94
1
Low fuel pressure; warning threshold exceeded
100
1
Low oil pressure; warning threshold exceeded
110
0
High coolant temperature; warning threshold exceeded
111
1
Coolant level too low
168
2
High battery voltage; warning threshold exceeded
174
0
High low fuel temperature; warning threshold exceeded
175
0
High oil temperature; warning threshold exceeded
13-11.
Engine Diagnostic Display
Engine diagnostic
1
2
0 of
3
0
SPN:
5
Engine Diagnostics
0
1
2
3
4
4
FMI
0
5
6
6
OC:
Ok
Prev
Next
Hide
0
7
Get
Faults
10
Diagnostic Description
Requesting/Ok
Requesting appears on the display
as the display communicates with
the engine controller. Once all diagnostic codes are available, Ok appears on the display.
7
11
9
Diagnostic Display
Indicates Number Of Faults
Suspect Parameter Number
Failure Mode Identifier
The SPN and FMI numbers are
generated by the engine controller
according to the J1939 standard.
Dm2. DiagnosticString
8
codes are
for use by the engine Factory
Authorized Service Agent only.
Attempting engine repair may
void engine warranty.
Occurrence Count
For non−critical faults, the number of occurrences of each fault
can accumulate.
8 Previous Function Button
9 Next Function Button
10 Hide Function Button
Non−critical faults can be hidden.
11 Get Faults Function Button
OM-259 705 Page 81
13-12. Main Menu Access Code
1
ENTER PASSWORD
1
2
0000
3
4
+
>
Cancel
Access Code (Password)
The factory set access code is
1000. This access code is not programmable and cannot be
changed.
2
4
Access Code Display
An access code is required to gain
access to the main menu. This display appears whenever the Menu/
Cancel function button is pressed
while in the 1-Up or 6-Up display
Use the increase function button to
increase the value underlined. Use
the > function button to move to the
next digit.
Enter
5
3
Increase Number Function
Button
Go to Next Number Function
Button
6
5
6
Cancel Function Button
Enter Function Button
1
2
3
Main Menu
Cursor
Scroll Function Buttons
13-13. Main Menu Options − Resetting Hours At Oil Change
Use scroll function buttons to move
cursor.
1
Brightness
Contrast
Units
Reminders
OEM
Version
Stored Codes
Language
0%
0
English
4
Select Function Button
When the cursor is in desired position, press Select function button to
go to sub-menu.
2
5
Service Reminders Display
Move cursor to select engine or
compressor and press Select function button. The appropriate
Change Oil display appears.
6
English
Reset Function Button
Press the Reset function button to
reset Remaining Hours after changing oil.
4
3
Change Engine Oil
5
Service Reminder IntervalRemaining
Engine Oil
500
0
Compressor Oil
1000
490
6
OM-259 705 Page 82
Modify Reset Cancel
13-14. Main Menu Options: Brightness, Contrast, And Units
1
2
3
Use scroll function buttons to move
cursor.
2
1
4
Brightness
Contrast
Units
Reminders
Select Function Button
When the cursor is in desired position, press Select function button to
go to sub-menu.
0%
0
English
OEM
Version
Stored Codes
Language
Main Menu
Cursor
Scroll Function Buttons
5
Brightness Menu Display
Use scroll function buttons to increase or decrease display
brightness. When desired percentage is reached, press Select
function button.
6
English
4
Contrast Menu Display
Use scroll function buttons to increase or decrease display contrast (lightness/darkness). Contrast range is 0 to 175. Viewing
angle affects appearance of display. When desired contrast is
reached, press Select function
button.
7
Units Menu Display
Use scroll function buttons to scroll
through choices:
3
English (PSI, F)
5
Bar (Bar, C)
Brightness
Kpa (Kpa, C)
0%
When desired units configuration
is reached, press Select function
button.
6
Contrast
0
7
Units
English
OM-259 705 Page 83
13-15. Main Menu Options − Reminders
1
2
3
Use scroll function buttons to move
cursor.
2
1
4
Brightness
Contrast
Units
Reminders
OEM
Version
Stored Codes
Language
Select Function Button
When the cursor is in desired position, press Select function button to
go to sub-menu.
0%
0
English
5
Service Reminders Display
Move cursor to select engine or
compressor and press Select function button. The appropriate
Change Oil display appears.
6
Reset Function Button
Press the Reset function button to
reset Remaining Hours after changing oil.
English
7
4
5
Main Menu
Cursor
Scroll Function Buttons
Modify Function Button
NOTICE − The service interval can
be modified. Shorter service intervals may be appropriate during
heavy use or in certain environments (such as dusty or extreme
temperatures). Lengthening service intervals is not recommended
and could result in voiding engine
warranty.
3
8
9
Service Reminder IntervalRemaining
Engine Oil
500
0
Compressor Oil
1000
490
Increase Number Function
Button
Go to Next Number Function
Button
Use the increase function button to
increase the value underlined. Use
the > function button to move to the
next digit.
10 Cancel Function Button
11 Enter Function Button
Change Engine Oil
Change Engine Oil
000000H
+
8
6
>
Cancel
Modify Reset Cancel
7
OM-259 705 Page 84
9
10
Enter
11
13-16. Main Menu Options − OEM, Version, Stored Codes, And Language
1
2
3
Main Menu
Cursor
Scroll Function Buttons
Use scroll function buttons to move
cursor.
2
1
Brightness
Contrast
Units
Reminders
5
7
OEM
Version
Stored Codes
Language
4
Select Function Button
When the cursor is in desired position, press Select function button to
go to sub-menu.
0%
0
English
5
OEM Menu Option
This menu option is for Factory Authorized Service Agents only and is
password protected.
6
Version Menu Display
The information in this display may
be requested by a Factory Authorized Service Agent during
troubleshooting.
7
English
4
8
Stored Codes
Stored codes can also be accessed
when the initial Service Reminder
display appears as the engine controller is initiating (see Sections
13-4 and 13-11).
8
Language Menu Display
Use scroll function buttons to
scroll through choices: English,
French, Italian, Spanish, and
Brazilian Portuguese. When desired language is reached, press
Select function button.
3
6
Configuration
Bootloader
Firmware
Part Number
0.0.0.0
00.00.
00.00
00.00.
00.00
XX−XX−XXXX
Version
OM-259 705 Page 85
SECTION 14 − RUN-IN PROCEDURE
run_in2 2014−10
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.
14-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1
Welder/Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
2
NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/generator is kept loaded during run-in.
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
1
OM-259 705 Page 86
See the engine manual for additional
engine run-in information.
14-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
1
7
2
4
3
5
+
3
6
S-0683 / S-0684
!
Stop engine.
!
Do not touch hot exhaust pipe, engine parts, or load bank/grid.
!
Keep exhaust and pipe away from
flammables.
NOTICE − Do not perform run-in
procedure at less than 20 volts weld output
and do not exceed duty cycle or equipment
damage may occur.
1 Load Bank
Turn all load bank switches Off. If needed,
connect load bank to 115 volts ac wall
receptacle or generator auxiliary power
receptacle.
2 Welder/Generator
Place Welder Selector switch in the A
position (Single Operator) and rotate A/V
control to minimum. Place Process Selector switch in Stick position.
3
Weld Cables
Connect load bank or resistor grid to
generator Side A weld output terminals
using proper size weld cables with correct
connectors. Observe correct polarity.
4
Resistance Grid
Use grid sized for generator rated output.
Turn Off grid.
5
Voltmeter
6
Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several minutes.
For Load Bank
Set load bank switches and then adjust
generator A/V control so load equals
rated voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manual).
For Resistance Grid
Set grid switches and then adjust generator A/V control so load equals rated
voltage and current of the generator
(see nameplate, rating label, or the
specifications section in this manual).
Check generator and meters after first five
minutes then every fifteen minutes to be
sure generator is loaded properly.
NOTICE − Check oil level frequently during
run-in; add oil if needed.
It is recommended to run the welder/generator for two hours minimum and up to four
hours under load. Place A/V control in
minimum position, then shut down load
bank or grid to remove load. Run engine
several minutes at no load.
! Stop engine and let cool.
7 Engine Exhaust Pipe
Repeat procedure if wetstacking is present.
OM-259 705 Page 87
SECTION 15 − AIR COMPRESSOR TABLES
15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
Orifice Diameter (in) And Free Air Flow (CFM)
Gauge Pressure (psi)
1/64
1/32
3/64
1/16
3/32
1/8
3/16
1/4
1
0.027
0.107
0.242
0.430
0.97
1.72
3.86
6.85
2
0.038
0.153
0.342
0.607
1.36
2.43
5.42
9.74
3
0.046
0.188
0.471
0.750
1.68
2.98
6.71
11.9
5
0.059
0.242
0.545
0.965
2.18
3.86
8.71
15.4
10
0.084
0.342
0.77
1.36
3.08
5.45
12.3
21.8
15
0.103
0.418
0.94
1.67
3.75
6.65
15.0
26.7
20
0.119
0.485
1.07
1.93
4.25
7.7
17.1
30.8
25
0.133
0.54
1.21
2.16
4.75
8.6
19.4
34.5
30
0.156
0.632
1.40
2.52
5.6
10.0
22.5
40.0
35
0.173
0.71
1.56
2.80
6.2
11.2
25.0
44.7
40
0.19
0.77
1.71
3.07
6.8
12.3
27.3
49.1
45
0.208
0.843
1.9
3.36
7.6
13.4
30.3
53.8
50
0.225
9.14
2.05
3.64
8.2
14.5
32.8
58.2
60
0.26
1.05
2.35
4.2
9.4
16.8
37.5
67.0
70
0.295
1.19
2.68
4.76
10.7
19.0
43.0
76.0
80
0.33
1.33
2.97
5.32
11.9
21.2
47.5
85.0
90
0.364
1.47
3.28
5.87
13.1
23.5
52.5
94.0
100
0.40
1.61
3.66
6.45
14.5
25.8
58.3
103.0
110
0.43
1.76
3.95
7.00
15.7
28.0
63.0
112.0
120
0.47
1.90
4.27
7.58
17.0
30.2
68.0
121.0
130
0.50
2.04
4.57
8.13
18.2
32.4
73.0
130.0
140
0.54
2.17
4.87
8.68
19.5
34.5
78.0
138.0
150
0.57
2.33
5.2
9.20
20.7
36.7
83.0
147.0
175
0.66
2.65
5.94
10.6
23.8
42.1
95.0
169.0
200
0.76
3.07
6.90
12.2
27.5
48.7
110.0
195.0
OM-259 705 Page 88
15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At
70-90 P.S.I.G.
MISCELLANEOUS
PORTABLE
TOOLS
Percent Use Factor And
Compressed Air Consumption (CF)
Percent Use Factor And
Compressed Air Consumption (CF)
1 min
MISCELLANEOUS
PORTABLE
TOOLS
8.75
25
Burring Tool, Large
3.6
6.0
8.4
24
8.75
12.25
35
Rammers, Small
3.9
3.25
9.1
13
1.8
3.0
4.2
12
Rammers, Medium
5.1
8.5
11.9
34
Screwdriver,
#6 to 5/16” Screw
3.6
6.0
8.4
24
Rammers, Large
6.0
10.0
14.0
40
Tapper, to 3/8”
3.0
5.0
7.0
20
Backfill Tamper
3.75
6.25
8.75
25
Nutsetters, to 3/8”
3.6
6.0
8.4
24
Compression Riveter
Nutsetters, to 3/4”
4.5
7.5
10.5
30
Air Motor,
1 Horsepower
3.75
6.3
8.75
25
Impact Wrench, 1/4”
2.25
3.75
5.3
15
Air Motor,
2 Horsepower
7.5
12.5
17.5
50
Impact Wrench, 3/8”
3.0
5.0
7.0
20
Impact Wrench, 5/8”
4.5
7.5
10.5
30
Air Motor,
3 Horsepower
11.25
18.75
26.3
75
Impact Wrench, 3/4”
5.25
8.75
12.25
35
Paint Spray Gun
(Production)
3.0
5.00
7.00
20
Impact Wrench, 1”
6.75
11.25
15.75
45
,HAMMERS
Impact Wrench, 1-1/4”
8.25
13.75
19.2
55
Scaling Hammer
1.3
3.0
4.2
12
Die Grinder, Small
Die Grinder, Medium
2.25
3.6
3.75
6.0
5.3
8.4
15
24
Chipping Hammer
4.5
7.5
10.5
30
Horizontal Grinder, 2”
3.0
5.0
7.0
20
Riveting Hammer,
Light
2.25
3.75
5.25
15
Horizontal Grinder, 4”
9.0
15.0
21.0
60
Horizontal Grinder, 6”
9.0
15.0
21.0
60
Riveting Hammer,
Heavy
4.5
7.5
10.5
30
Horizontal Grinder, 8”
12.0
20.0
28.0
80
Circular, 8”
6.75
11.25
15.75
45
Circular, 12”
9.75
16.25
23.8
65
5.25
8.75
12.25
35
Chain, Lightweight
4.20
7.0
9.8
28
9.0
15.0
21.0
60
Chain, Heavy Duty
13.1
21.8
30.5
87
Vertical Grinders and
Sanders, 9” Pad
10.5
17.5
24.5
70
Burring Toll, Small
2.25
3.75
5.3
15
9 sec
15 sec
21 sec
Drill, 1/18” to 3/8”
3.75
6.25
Drill, 3/8” to 5/16”
5.25
Screwdriver,
#2 to #6 Screw
Vertical Grinders and
Sanders, 5” Pad
Vertical Grinders and
Sanders, 7” Pad
9 sec
15 sec
21 sec
1 min
0.2 cu. ft. per cycle
SAWS
Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)
OM-259 705 Page 89
SECTION 16 − 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.
16-1. Selecting Equipment
1
2
1
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
!
2
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2014−09 − ST-800 577
16-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
OM-259 705 Page 90
3
Metal Vehicle Frame
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
!
Bed liners, shipping skids, and
some running gear insulate the
welder/generator from the vehicle
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
16-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
3
GND/PE
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
16-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 16-8).
VOLTS 115
AMPS 4.5
Hz
60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-259 705 Page 91
16-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
16-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-259 705 Page 92
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
16-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in.
3/8 in.
1/2 in.
6-1/2 in.
7-1/4 in.
8-1/4 in.
9 in.
10 in.
14 in.
6 in.
8 in.
10 in.
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in.
2 HP, 14 in.
Standard 9 in.
Heavy Duty 12 in.
1/3 HP
18 in.
HID
Metal Halide
Mercury
Sodium
Vapor
400 GPH
900 GPH
3/4 HP, 16 in.
1 HP, 20 in.
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-259 705 Page 93
16-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welder/generator amperage output
must be at least twice the motor’s
running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
16-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-259 705 Page 94
16-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s Manual and national, state, and local codes.
Customer-supplied equipment
4
3
!
Welding
Generator
Output
is required if generator will supply standby power during
emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
5
Essential
Loads
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welder/Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 16-4).
OM-259 705 Page 95
16-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-259 705 Page 96
6
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2015-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2015 Miller Electric Mfg. Co.
2015−01
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