Miller BOBCAT 250 DIESEL User manual

Miller BOBCAT 250 DIESEL User manual
OM-258413H
2019−02
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welder/Generator
™
Bobcat 250 Diesel
File: Engine Drive
For product information,
Owner’s Manual translations,
and more, visit
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, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
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 Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Engine Prestart Checks And Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or
other reproductive harm.
S Always start and operate the engine in a well-ventilated area.
S If in an enclosed area, vent the exhaust to the outside.
S Do not modify or tamper with the exhaust system.
S Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
TABLE OF CONTENTS
SECTION 6 − OPERATING THE WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Engine Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Weld Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Typical MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun . . . . . . . . . . . . . . . . . . . . .
6-6. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Replacing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Engine Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − GMAW WELDING (MIG) GUIDELINES WHEN USING A VOLTAGE-SENSING FEEDER .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2018−06
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on unit.
D 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!
D Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding
procedure are employed.
D 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).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D 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.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
D Stop engine on inverter and discharge input capacitors according
to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-258413 Page 1
FLYING METAL or DIRT can injure
eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D 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.
D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D 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.
D 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.
D 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.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
D
D
D
D
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.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
OM-258413 Page 2
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
D 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).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D 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.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D 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.
D Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D 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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder — explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D 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.
D
D
D
D
D
D
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
FUEL can cause fire or explosion.
D
D
D
D
D Stop engine and let it cool off before checking or
adding fuel.
D 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.
D Keep away from moving parts such as fans,
belts, and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Stop engine before installing or connecting unit.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
D Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
D Do not let engine exhaust sparks cause fire.
D Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D 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.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
D Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
D NEVER use inside a home or garage, EVEN IF
doors and windows are open.
D Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
D Do not locate unit on, over, or near combustible
surfaces or flammables.
D Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
D 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.
D 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.
D Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
D Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
D Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
D Use only components and accessories approved by the manufacturer.
D Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
D Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-258413 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D Do not cut or gouge near flammables.
D Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
D Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
D Relieve pressure before disconnecting or connecting air lines.
D Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
D Do not direct air stream toward self or others.
D 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.
D Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
D If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
D Do not use compressed air for breathing.
D Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
D 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.
D Keep away from moving parts such as fans,
belts and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
D Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
D Do not touch hot compressor or air system
parts.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
D 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.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
OVERHEATING can damage motors.
D Turn off or unplug equipment before starting or
stopping engine.
D Do not let low voltage and frequency caused by
low engine speed damage electric motors.
D Use only equipment suitable for operation on 60 or 50/60 Hz
power.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
D Use correct procedures and equipment of adequate capacity to
lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D 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-258413 Page 4
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
D
D
D
D
D
D
D 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.
D Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
D Have only qualified persons do battery charging work.
D 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.
D 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.
D Do not charge a frozen battery.
D Do not use damaged charging cables.
D Do not charge batteries in a closed area or where ventilation is
restricted.
D Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
D Before charging battery, select correct charger voltage to match
battery voltage.
D Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
D Keep charging cables away from vehicle hood, door, or moving
parts.
HIGH PRESSURE FLUIDS can injure or kill.
D Engine fuel system components can be under
high pressure.
D Before working on fuel system, turn off engine
to release pressure.
D If any fluid is injected into the skin or body seek medical help immediately.
TILTING OF TRAILER can injure.
D Use tongue jack or blocks to support weight.
D Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
D 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.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
perform this installation.
D The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D
D
D
D 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-258413 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
D Always start and operate the engine in a well−ventilated
area.
D If in an enclosed area, vent the exhaust to the outside.
D Do not modify or tamper with the exhaust system.
D Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
For Standards regulating hydraulic systems, contact the National Fluid
Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
WI 53214 (phone: (414) 778-3344, website: www.nfpa.com).
Battery Service Manual, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.batterycouncil.org).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-258413 Page 6
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2018−06_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. L’électrode et le circuit de soudage sont
sous tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le
dévidoir, le logement des galets d’entraînement et
les pièces métalliques en contact avec le fil de
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant pas de trous.
D 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.
D Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D 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.
D 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!
D Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.
D 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).
D Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
D 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.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D 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.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
D Ne pas enrouler les câbles autour du corps.
D 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.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
D Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
d’une tension de circuit−ouvert double.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
OM-258413 Page 7
D 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.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D 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.
D Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
D Arrêtez le moteur sur l’onduleur et déchargez les condensateurs
d’entrée conformément aux instructions du manuel avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D 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.
D 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.
D 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.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D 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.
D 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.
D 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.
D 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-258413 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D 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.
D 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).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D 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.
D 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.
D 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.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D 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).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
D 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.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D 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.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D 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.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
manipuler avec précaution.
D 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.
D 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.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D 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.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D 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.
D Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D 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.
D Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
D 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.
D Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
D 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.
D Observer la polarité correcte (+ et −) sur les batteries.
D Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
D 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.
D Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
D Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
D Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
D Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
D Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
D Jeter les chiffons dans un récipient ignifuge.
D Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
D S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
D Maintenir fermés et verrouillés les portes,
recouvrements et dispositifs de protection.
panneaux,
D Arrêter le moteur avant d’installer ou brancher l’appareil.
D 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.
D Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-258413 Page 9
D Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D 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.
D Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
D Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
D Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
D Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D 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.
D Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
D Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
D Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
D 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.
D Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
D JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
D 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.
D Ne pas renverser la batterie.
D Remplacer une batterie endommagée.
D Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
D Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
D 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.
D 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.
D 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.
D 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.
D 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.
D 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.
D Utiliser uniquement des composants et accessoires homologués
par le fabricant.
D 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.
D Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
OM-258413 Page 10
MÉTAL CHAUD provenant du découpage
ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
D Ne pas découper ou gouger à proximité de produits inflammables.
D Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
D 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.
D Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
D 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.
D Ne pas diriger un jet d’air vers soi−même ou vers autrui.
D 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.
D 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.
D Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
D 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.
D Ne pas inhaler d’air comprimé.
D 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.
D 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.
D S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
D Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D 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.
D 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.
D 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.
D Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
D Prévoir une période de refroidissement avant
d’intervenir sur l’équipement.
D 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.
D 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.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D 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.
D
D
D
D
D Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
D Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
D 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.
D Utiliser uniquement des équipements adéquats pour un fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D 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.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-258413 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.
D Toujours porter une protection faciale, des gants en caoutchouc
et vêtements de protection lors d’une intervention sur la batterie.
D 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.
D Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
D 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.
D Observer la polarité correcte (+ et −) sur les batteries.
D Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
D 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.
D Suivre les instructions du fabricant de la batterie lors d’opérations sur
une batterie ou à proximité de celle−ci. Voir le manuel de service de
batterie (indiqué dans Normes de sécurité) pour plus d’informations.
D Les opérations de charge de batterie ne doivent être effectuées que
par des personnes qualifiées.
D 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.
D 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.
D Ne pas charger une batterie gelée.
D Ne pas utiliser de câbles de charge endommagés.
D Ne pas charger des batteries dans un espace fermé ou en l’absence
d’une ventilation.
D Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
D Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
D 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.
D Ranger les câbles de charge à distance du capot, des portes et des
pièces mobiles du véhicule.
LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.
D Les composants du système d’alimentation
peuvent contenir du carburant sous pression
élevée.
D Avant d’intervenir sur le système d’alimentation de carburant,
arrêter le moteur pour dépressuriser le système.
D En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D 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.
D Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
OM-258413 Page 12
D Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D 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.
D Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
D Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
D 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.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D 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.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D 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.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D 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).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles
que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation
de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Pour les moteurs diesel :
AVERTISSEMENT : les gaz d’échappement de moteurs diesel
vous exposent à des produits chimiques, reconnus par l’État
de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
D Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
D Si la zone est fermée, diriger l’échappement vers l’extérieur.
D Ne pas modifier ni altérer le système d’échappement.
D Ne pas faire tourner le moteur au ralenti, sauf si nécessaire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West
Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
778-3344, site web : www.nfpa.com).
Manuel de service de batterie, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
1-312-245-1074, site Web : www.batterycouncil.org).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: par exemple, des restrictions
d’accès pour les passants ou une évaluation individuelle des risques
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-258413 Page 13
. Complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbol Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2017−04
Moving parts can injure.
Safe100 2012−08
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 Symbol Definitions
A
V
X
U0
U2
I
I2
h
OM-258413 Page 14
Amperage
Negative
Read Operator’s
Manual
Voltage
Positive
Welding (General)
Duty Cycle
Direct Current
(DC)
Shielded Metal
Arc Welding
(SMAW)
Rated No−Load
Voltage (OCV)
Alternating
Current (AC)
Gas Metal Arc
Welding (GMAW)
Conventional
Load Voltage
Protective Earth
(Ground)
Current
Supplementary
Protector
Circuit Breaker
Rated Welding
Current
Output
Seconds
Work Connection
Hours
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Do Not Switch
While Welding
Clock, Time
Switch
. Complete Parts List is available at www.MillerWelds.com
Engine Oil
Glow Plug
Temperature
Fuel
Air Filter
Call for
Maintenance
Battery (Engine)
Hour Meter
Check Valve
Clearance
Engine
Idle (Slow)
Single Phase
Alternator
Engine
Run (Fast)
Engine Start
(Engine RPM)
Belt Drive
Hz
Hertz
Engine Coolant
Temperature
Engine Stop
Notes
OM-258413 Page 15
. Complete Parts List is available at www.MillerWelds.com
Notes
OM-258413 Page 16
. Complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Weld, Power, and Engine Specifications
. This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Welding
Mode
Weld Output
Range
Rated
Welding
Output
Maximum
Open Circuit
Voltage
CC/AC
40 − 250 A
250 A, 25 V,
100% Duty
Cycle
80
CC/DC
40 − 250 A
250 A, 25 V,
100% Duty
Cycle
80
CV/DC
17 − 28 V
275 A, 25 V,
60% Duty
Cycle
250 A, 28 V,
100% Duty
Cycle
Generator Power Rating
Engine
Liquids
Capacity
Peak: 11 kVA/kW
41
Continuous: 9.5 kVA/kW,
Single-Phase,
80/40 A, 120/240 V AC,
60 Hz
(while not welding)
Fuel: 12 gal
(45 L) Tank
Oil: 3.4 qt
(3.2 L)
Engine
Kubota D722
Water-Cooled,
Three-Cylinder
Four-Cycle
Diesel Engine
Producing 19 HP @ 3600
RPM (Weld Speed)
2450 RPM Idle Speed
Sound Level At Rated
Output:
79.5dB (105.0 Lwa) @ 7 m
4-3. Environmental Specifications
A. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
−20 to 104°F (−29 to 40°C)
−40 to 131°F (−40 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
OM-258413 Page 17
. Complete Parts List is available at www.MillerWelds.com
4-4. Dimensions, Weights, And Operating Angles
!
Do not exceed tilt angles or
engine could be damaged or
unit could tip.
!
Do not move or operate unit
where it could tip.
Weight: 638 lb (289 kg)
Lifting Eye Weight
Rating: 1250 lb (567 kg)
Support Assembly Dimensions
259 701 / 259 702
OM-258413 Page 18
. Complete Parts List is available at www.MillerWelds.com
4-5. Duty Cycle And Overheating
1
1
100% Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
. This unit is rated at 250 amperes for continuous welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
200 293
4-6. Static Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW process and drooping during the
SMAW and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welder/generator.
Notes
OM-258413 Page 19
. Complete Parts List is available at www.MillerWelds.com
4-7. Fuel Consumption
A typical job using 1/8 in 7018
electrodes (125 amps, 20%
duty cycle), expect about 24
hours of operation per fuel fill.
Welding at 150 amps at 40%
duty cycle uses approximately
1/2 gallon per hour, or about 22
hours of operation per fuel fill.
2.00
1.75
1.50
US Gal./Hr.
1.25
1.00
0.75
0.50
0.25
IDLE
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
2.00
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
0.25
IDLE
0.00
0
1
2
3
4
5
6
7
8
Aux Power KiloWatts at 100% DUTY CYCLE
9
10
260 051-A / 260 052-A
OM-258413 Page 20
. Complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welder/Generator
Movement
OR
!
Do not move or operate unit
where it could tip.
!
Do not lift unit from end.
!
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
!
Always securely fasten welder/
generator onto transport vehicle or trailer and comply with
all DOT and other applicable
codes.
NOTICE − Do not install unit where air
flow is restricted or engine may overheat.
. See Section 4-4 for lifting eye rating.
Location / Airflow Clearance
Mounting:
18 in
(460 mm)
18 in
(460 mm)
Do not mount unit by supporting the base only at the four
mounting holes. Do not use
flexible mounts. Use crosssupports to adequately support unit and prevent damage
to base.
1
Cross-Supports
OR
OR
18 in
(460 mm)
!
Mount unit on flat surface or use
cross-supports to support base.
18 in
(460 mm)
. Go to MillerWelds.com for more
information on truck installations.
18 in
(460 mm)
Mounting
1
install2 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
OM-258413 Page 21
. Complete Parts List is available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
rot_grnd2 2018−01 − 800652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
!
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
1
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
2
3
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
. Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-3. Installing Exhaust Pipe
!
Stop engine and let cool.
!
Do not blow exhaust toward
right side of unit where air inlet
is or air cleaner may need to be
replaced more often. Point exhaust pipe in desired direction
but always away from front
panel and direction of travel.
1
2
Exhaust Pipe
Exhaust Pipe Clamp
Tools Needed:
9/16 in. Or 14 mm
Slide clamp over muffler pipe. Slide
exhaust pipe onto muffler pipe and rotate exhaust pipe to desired position.
Secure exhaust pipe with clamp.
1
2
259 703
OM-258413 Page 22
. Complete Parts List is available at www.MillerWelds.com
5-4. Connecting The Battery
+
−
Tools Needed:
3/8, 1/2 in.
259 707 / Ref. S-0756-D
!
Connect negative (−) cable last.
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.
S Do not allow the battery cables to
touch opposing terminals. When connect-
ing the battery cables attach the positive
(+) cable to the positive (+) battery terminal first, followed by negative (−) cable to
negative (−) battery terminal.
S Never start the engine when the
cables are loose or poorly connected to
the battery terminals.
S Never disconnect the battery while
the engine is running.
S Never use a quick battery charger to
start the engine.
S Do not charge battery with Engine
Control switch On.
S Always disconnect the negative (−)
battery cable before charging battery.
Notes
OM-258413 Page 23
. Complete Parts List is available at www.MillerWelds.com
5-5.
Engine Prestart Checks And Overview
6
4
5
3
2
7
8
9
10
1
1
2
3
4
5
Generator Power Receptacles (see
Section 7)
Weld Output Terminals (see Section 5-7)
Operator Controls (see Section 6)
Fuel Gauge/Maintenance Display
Fuel Filler Cap
OM-258413 Page 24
6
7
8
9
10
11
Exhaust Pipe
Engine Maintenance Label
Radiator Cap
Water Bypass Hose
Oil Fill Cap
Coolant Overflow Bottle
12 Oil Filter
13 Oil Dipstick
14 Primary Fuel Filter
15 Inline Fuel Filter
16 Air Cleaner
. Complete Parts List is available at www.MillerWelds.com
!
Engine Left Side
Engine shown with doors removed. Doors must be in place when
engine is running.
Engine must be cold and on a level surface. See maintenance label (Section 8-5)
for fluid specifications.
Starting engine for the first time:
Fill tank with fresh fuel.
Check coolant level at radiator cap; add
coolant to radiator if necessary.
Daily pre-start checks:
Fill with fresh fuel.
Check oil. If oil is not up to full mark on dipstick, add oil. Unit is shipped with 10W30
engine oil.
Check coolant level in overflow bottle. If
coolant is below Low level, add coolant until level in tank is between Low and Full levels. If overflow bottle coolant level was low,
check coolant level in radiator (see Section 8-5).
Engine damage can result from:
13
12
11
S
S
S
S
S
S
Low oil level
High engine temperature
Incorrect coolant mixture
Running out of fuel (air in fuel lines)
Using gasoline
Using ether to start engine
Engine stops if oil pressure is low, engine
coolant temperature is high, or fuel level is
low. Some conditions may cause engine
damage before the engine shuts down.
Oil: Check oil level often and do not use
the oil pressure shutdown system to monitor oil level.
Engine Temperature: Incorrect engine
temperature can damage engine. Do not
run engine without a properly working thermostat and radiator cap.
Keep radiator and air intake louvers clean.
Coolant: A solution of 50% ethylene glycol base antifreeze and 50% water must
be used in this engine. Do not use 100%
antifreeze or severe damage will occur.
Fuel: Engine will shut down if fuel level is
low. Air in the fuel system causes starting
problems.
Do not use gasoline. Using ether voids
warranty.
. 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.
14
15
16
Engine Right Side
804 249-A / 804 250-A
OM-258413 Page 25
. Complete Parts List is available at www.MillerWelds.com
5-6. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
1/0 (60)
1/0 (60)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
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)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
5-7. Weld Output Terminals
!
Stop engine.
!
Failure to properly connect
weld cables may cause excessive heat and start a fire, or
damage your machine.
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged,
undersized, or repaired cables.
1
2
Work Weld Output Terminal
Electrode Weld Output Terminal
Connect work cable to Work terminal.
1
2
Connect electrode holder cable or
electrode weld cable to Electrode terminal for Stick and MIG welding.
Connect torch cable to Electrode terminal for TIG welding.
Use Process Selector switch to
select type of weld output (see
Section 6-2).
. See Sections 6-3 thru 6-5 for typical process connections and
control settings.
259 707 / 258 070-A
OM-258413 Page 26
. Complete Parts List is available at www.MillerWelds.com
5-8. Connecting To Weld Output Terminals
1
2
!
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 cable terminal and copper
bar. Make sure that the surfaces of the weld cable terminal
and copper bar are clean.
1
6
3
2
3
4
5
6
Correct Weld Cable
Connection
Incorrect Weld Cable
Connection
Weld Output Terminal
Supplied Weld Output
Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against copper bar.
4
5
Tools Needed:
3/4 in.
803 778-B
Notes
OM-258413 Page 27
. Complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATING THE WELDER/GENERATOR
6-1. Engine Control Switches
3
Glow Plug Time
70°F (21°C)
32°F (0°C)
−4°F (−20°C)
2
t
0 seconds
10 seconds
20 seconds
Do not use glow plugs longer than
20 seconds.
Do not use ether to start engine.
Using ether voids warranty.
1
Ref. 258 070-A / Ref. 259 237-B
NOTICE − Disconnect equipment from auxiliary power receptacles during start−up and
shutdown. Some equipment can be damaged
by changes in frequency as engine rpms
change during start-up and shutdown.
under load. In Run position, engine runs at
weld/power speed.
To Start: Use glow plug switch if necessary.
Turn Engine Control switch to Start position.
Release switch when engine starts.
. Place switch in Run position to operate
. If the engine does not start, let engine
1
2
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power speed
OM-258413 Page 28
most MIG equipment.
Glow Plug Switch
If necessary, push switch down before startup. See glow plug table for operating information.
come to a complete stop before attempting restart.
To Stop: Turn Engine Control switch to Off
position.
3
Fuel Gauge/Maintenance Display
See insert from maintenance label.
. Complete Parts List is available at www.MillerWelds.com
6-2. Weld Output Controls
1
2
3
Ref. 258 070-A
1
Weld Process Selector Switch
NOTICE − Do not switch while welding.
2
Coarse Range Switch
NOTICE − Do not switch while welding.
Use switch to select type of weld output.
Wire (GMAW) Welding: Use a positive (+)
position for Direct Current Electrode Positive
(DCEP) and a negative (−) position for Direct
Current Electrode Negative.
Use switch to select weld amperage range
when Weld Process Selector switch is in Stick/
Tig position, or voltage range when switch is in
Wire position.
Stick (SMAW) and TIG (GTAW Welding): Use
a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative (−) position for Direct Current Electrode Negative.
Use AC position for alternating current.
. For best arc starts and when using weld
and generator power together, use a low
Coarse Range setting with the Fine control set at 7 or higher.
3 Fine Control
Use control to select weld amperage (Stick/
Tig) or voltage (Wire) within the range selected
by the Coarse Range switch. Control may be
adjusted while welding.
Set control at 10 for maximum generator
power.
Weld output would be about 124 A DC based
on control settings shown (80% of 60 to 140
A). Settings shown are typical for welding with
a 7018 (1/8) electrode.
. See Sections 6-3 thru 6-5 for typical process connections and control settings.
OM-258413 Page 29
. Complete Parts List is available at www.MillerWelds.com
6-3. Typical Stick Welding Connections And Control Settings
!
Stop engine.
. This
section provides general
guidelines and may not suit all
applications.
Typical Settings For 7018 (1/8 in.)
Electrode:
>
>
>
Set Weld Process Selector
switch to + Stick position.
Set Coarse Range switch to
60-160 (1/8”) position.
Set Fine control at 7 or higher
for best results.
. Consult the amperage selection
1
2
tables below if welding with other
electrodes.
Work Clamp
Electrode Holder
Connect Work cable to Work terminal
and Electrode holder cable to Electrode terminal on welder/generator.
1
. Miller recommends Hobart filler
metals.
2
Tools Needed:
3/4 in.
259 707 / Ref 258 070-A
OM-258413 Page 30
. Complete Parts List is available at www.MillerWelds.com
6-4. Typical MIG Welding Connections And Settings
!
Stop engine.
. This section provides general guide-
lines and may not suit all applications.
Typical Control Settings For Short
Circuit Transfer Using .035 (ER70S-3)
Solid Wire And 75/25 Argon/CO2 Gas:
>
>
>
>
Set Weld Process Selector switch
to Wire + (DCEP) position.
Set Coarse Range switch to
Wire/17−22 Range position.
Set Fine Control to obtain minimum
spatter.
Set wire feed speed between
100-300 ipm.
Typical Control Settings For Spray
Transfer Using .035 (ER70S-3) Solid
Wire And 80% Or Higher Argon/CO2
Gas:
>
6
>
7
>
>
Set Weld Process Selector switch
to Wire + position.
Set Coarse Range switch to
Wire/20-28 Range position.
Set wire feed speed between
320-500 ipm.
Set Fine control to 3 and increase
for longer arc length.
Typical Control Settings Using .045
(E71T-11) Self-Shielded Flux Core
Wire:
>
>
>
>
2
>
3/4 in.
Set wire feed speed between
125-200 ipm.
4
Gun Trigger Plug
5
Voltage Sensing Clamp
6
Gas Cylinder:
75/25 Argon/CO2 Gas for Short
Circuit Transfer
80% Argon (Or Higher)/CO2 For
Spray Transfer
Work
Tools Needed:
Set Fine Control near minimum setting.
1
2
3
4
1
Set Coarse Range switch to
Wire/17-22 Range position.
Do a test weld. To increase arc
length, increase Fine Control setting. To shorten arc length, reduce
fine control setting or increase wire
feed speed.
Work Clamp
Wire Feeder
MIG Gun
3
5
Set Weld Process Selector switch
to Wire − position (DCEN).
7
Gas Hose
Connect work cable to welder/generator
Work terminal. Connect cable from wire
feeder to cable from welder/generator
Electrode terminal.
. Miller recommends Hobart filler met259 707 / Ref 258 070-A / Ref. 802 766-C
als.
OM-258413 Page 31
. Complete Parts List is available at www.MillerWelds.com
6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun
Tools Needed:
3/4 in.
10
9
8
Work
12
Not Used
6
5
To Work
Left Side View
2
1
3
11
4
5
6
7
259 707 / Ref. 258 070-A / Ref. 802 750-A
!
Stop engine.
. This section provides general guide-
>
lines and may not suit all applications.
Typical Settings For 4043 (.035)
Aluminum On 1/8 in. Material:
>
>
>
Set Weld Process Selector switch to
Wire + (DCEP) position.
Set Coarse Range switch to
Wire/17-22 Range position.
Set Fine Control to desired voltage
(arc length). Start with a low voltage
setting (about 4) to prevent burnback.
OM-258413 Page 32
1
2
3
4
5
6
7
Set wire feed speed between 240-270
ipm. For 1/4 in. (6 mm) and thicker
materials, set Coarse Range switch to
Wire/20−28 and Fine Control to 6. Increase/decrease Fine Control setting
to increase/decrease arc length.
Weld Control
Spoolgun
Optional Contactor (Recommended)
Reed Switch
Weld Cable (Customer-Supplied)
Weld Control Weld Terminal
Weld Power Cable From Spoolgun
8 Work Clamp
9 Gas Hose
10 100% Argon Cylinder
11 Trigger Control Cord
12 Input Power Cord
Route weld cable from welder/generator
Electrode terminal through reed switch to
unused contactor terminal. Connect weld
cable from spoolgun to weld control weld
terminal (item 6).
Connect work cable to welder/generator
Work terminal.
. Miller recommends Hobart filler metals.
. Complete Parts List is available at www.MillerWelds.com
6-6. Fuel/Hour Gauge Descriptions
OM-258413 Page 33
. Complete Parts List is available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles
1
4
3
5
2
259 707 / 258 070
!
!
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.
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is
11.0 kVA/kW.
CB2 protects RC2 and CB3 protects RC3
from overload. If a supplementary protector
opens, the receptacle does not work.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.
. Press button to reset supplementary
Unplug power cord before attempting to service accessories or tools.
!
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
current increases.
3
Supplementary Protector CB1
Set Fine Control R1 at 10 for full generator power.
CB1 protects receptacles RC1, RC2, and
RC3 from overload. If CB1 opens, the receptacles do not work. Place switch in On
position to reset.
. Generator power decreases as weld
1
2
120/240 V 50 A AC Receptacle RC1
120 V 20 A AC Receptacles RC2
and RC3 (GFCI Receptacles Shown)
OM-258413 Page 34
4
Supplementary Protector CB2
5
Supplementary Protector CB3
protector. If supplementary protector
continues to open, contact Factory
Authorized Service Agent.
Combined output of all receptacles limited
to 11.0 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 23 A is available
at the 120/240V receptacle:
2 x (120 V x 20 A) + (240 V x 26 A) = 11.0
kVA/kW
. Miller recommends Hobart filler metals.
. Complete Parts List is available at www.MillerWelds.com
7-2. GFCI Receptacle Information, Resetting, And Testing
. Alternate
location for red
and green indicator LEDs.
1
2
5
4
3
. Orientation of receptacle may be different in other applications.
RotGFCI1 2018-12
!
!
1
2
3
4
5
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
Unplug power cord before attempting to service accessories or tools.
120 V 20 A AC GFCI Receptacle
GFCI Receptacle Test Button
GFCI Receptacle Reset Button
Red GFCI Indicator Light (LED)
Green GFCI Indicator Light (LED)
. Red and Green indicator lights may be
combined in a single LED.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting/Testing GFCI Receptacle
!
Test GFCI monthly.
!
If Red LED blinks, stop using GFCI
receptacle and have a Factory Authorized Service Agent replace it.
!
Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place engine control switch in
RUN position, and press GFCI Reset button. Reconnect equipment to GFCI receptacle. If GFCI Reset button pops out again,
check the equipment and repair or replace
if faulty.
Testing GFCI Receptacles
Start engine and place engine control
switch in Run position. Press the GFCI Test
button. The GFCI Reset button should pop
out.
Press the GFCI Reset button.
Have a Factory Authorized Service
Agent replace GFCI if any of the following occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
OM-258413 Page 35
. Complete Parts List is available at www.MillerWelds.com
7-3. Simultaneous Weld And Power
Weld Current in Amperes
Total Power in Watts
120 V Full kVA Receptacle
Amperes
240 V Full kVA Receptacle
Amperes
250
2200
18
9
180
3500
29
14
125
5200
43
21
90
8000
66
33
0
11,000 (Peak)
84
42
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
Current Available in Amperes
240 V
Receptacle*
Each 120 V Duplex
Receptacle
42
37
32
27
22
0
5
10
15
20
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
1
3
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available using
120/240 V Plug
4
V x A = Watts
*One 240 V load or two 120 V loads.
120V
5
120V
240V
Plug Wired for 120/240 V,
3-Wire Load
6
2
Tools Needed:
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-258413 Page 36
. Complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Maintenance Label
OM-258413 Page 37
. Complete Parts List is available at www.MillerWelds.com
8-2. Routine Maintenance
!
Recycle engine
fluids.
* To be done by Factory Authorized Service Agent
n = Check
Z = Change
~ = Clean
Stop engine before maintaining.
. See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
l = Replace
Reference
Every
8
Hours
Section 5-5
n Coolant Level
n Fuel Level
n Oil Level
~ Oil, Fuel Spills
Every
200
Hours
Section 8-5,
8-3, Engine
Manual
n Fuel Connections
Z Oil
Z Oil Filter
l Air Cleaner
n Engine Speed
l Unreadable Labels
~ Weld Terminals
~ Battery Terminals
5/16 in.
(8 mm)
n Belt Tension
Every
400
Hours
Z Fuel Filters
nl Weld Cables
Every
1000
Hours
Engine
Manual,
Section 8-5,
8-6
n Fan Belt
~ Flush Radiator
n Valve Clearance*
n Slip Rings*
n Brushes*
n Radiator Hoses
Every
2000
Hours
n Air Cleaner Hoses
Engine
Manual,
Section 8-5
nl Fuel Hoses
OM-258413 Page 38
nl Coolant & Hoses
~ Injectors*
. Complete Parts List is available at www.MillerWelds.com
8-3. Replacing Air Cleaner
!
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
1
Air Intake Tube
2
Hose Clamp
3
Air Cleaner
Loosen hose clamp, slide air cleaner towards rear of unit and remove. Slide new
air cleaner onto intake tube and tighten
clamp.
Replace air cleaner every 200 hours or
less if used in severe conditions.
3
1
2
259 707
8-4. Overload Protection
!
Tools Needed:
Stop engine.
. When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in.
1
Fuse F1
F1 protects the weld excitation
winding from overload. If F1 opens,
weld output stops or is low.
2
Fuse F2
F2 protects the generator power
excitation winding from overload. If
F2 opens, generator power output
stops or is low.
1
3
Circuit Breaker CB7
CB7 protects the engine glow plug
circuit. If CB7 opens, the glow plug
will not heat. CB7 automatically resets when the fault is corrected.
2
4
3
Supplementary Protector CB8
CB8 protects the engine battery circuit. If CB8 opens, the engine will
not crank. CB8 automatically resets when the fault is corrected.
4
Replace any open fuses. Close
door and/or reinstall cover before
operating unit.
259 707
OM-258413 Page 39
. Complete Parts List is available at www.MillerWelds.com
8-5.
Engine Maintenance Activities
6
5
7
8
3
2
4
3
1
259 707
!
Stop engine and let cool.
Oil And Fuel
1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter according to engine manual.
NOTICE − Close valve and valve cap before
adding oil and running engine.
Fill crankcase with new oil to full mark on dipstick (see Section 5-5).
3 Fuel Lines
Replace fuel lines if cracked or worn.
4 Inline Fuel Filter
Install new filter as shown.
OM-258413 Page 40
5
Primary Fuel Filter
Replace filter according to engine manual.
Wipe up any spilled fuel.
Start engine, and check for fuel leaks.
!
Stop engine, tighten connections as
necessary, and wipe up fuel.
Coolant
6
Radiator Cap
7
Radiator Drain Cock (Located on bottom of radiator)
Drain engine coolant according to procedure in engine manual.
Add engine coolant as follows:
8
Water Bypass Hose
Remove water bypass hose. Add coolant to
radiator until coolant trickles out of water bypass hose. This ensures all air is purged
from the system.
Reinstall hose and radiator cap. Check coolant level in overflow bottle.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
. Complete Parts List is available at www.MillerWelds.com
8-6. Adjusting Engine Speed
. If engine does not start and stop properly, verify fuel solenoid is installed properly before adjusting engine speed (see Sections A and B following).
If engine does not stay at idle speed, verify the throttle solenoid is installed and adjusted properly before adjusting engine speed (see Section
C following).
If engine runs properly but the speeds are incorrect, do not adjust the solenoids. Adjust engine speed according to the instructions in Section
D.
A. Checking Fuel Solenoid Off Position
3
6
Minimum:
1/16 in.
(1.5mm)
Top View
7
2
5
. Stop
screw is
factory-set and
should not be
adjusted.
1
Push
in.
4
Tools Needed:
3/8, 7/16 in.
10, 14 mm
!
Stop engine.
If the engine is low on power or does not
start and stop when using the Engine Control switch, check the position of the fuel
solenoid in the Off and Run positions, and
check solenoid movement.
Checking Solenoid Off Position
1 Throttle Solenoid Plunger
2 Throttle Solenoid
3 Fuel Solenoid
4
5
6
7
Shutdown Lever
Shutdown Stop Screw
Fuel Solenoid Jam Nut
Shutdown Lever Vertical Arm
. Stop screw is factory-set and should
not be adjusted.
Manually push throttle solenoid plunger into the throttle solenoid body; hold plunger in
this position to ensure the fuel solenoid is in
the Off position.
Verify shutdown lever contacts the shutdown stop screw. If shutdown lever does
not contact shutdown stop screw, verify the
fuel solenoid jam nut has at least 1/16 in.
(1.5 mm) clearance from solenoid body. If
the jam nut contacts the solenoid body,
carefully bend the vertical arm of the shutdown lever away from the fuel solenoid until
there is at least 1/16 in. (1.5 mm) of clearance between the jam nut and solenoid
body.
Ref. 259 852
OM-258413 Page 41
. Complete Parts List is available at www.MillerWelds.com
B. Checking Fuel Solenoid Run Position
!
Stop engine.
If the engine is low on power or does not
start and stop when using the Engine
Control switch, check the position of the
fuel solenoid in the Off and Run positions,
and check solenoid movement.
1
2
3
4
5
6
7
8
Top View
Fuel Solenoid Plunger
Fuel Solenoid
Shutdown Lever
Shutdown Lever Vertical Arm
Adjustment Screw Housing
Fuel Solenoid Jam Nut
Block Pin
Fuel Solenoid Mounting Screws
Checking Solenoid Run Position
8
Turn Engine Control switch to the Run position. Manually push fuel solenoid plunger into the fuel solenoid body. (This action will hold the plunger in the Run/energized position.)
1
Verify the vertical arm of the shutdown
lever contacts or is within 1/16 in. (1.5
mm) of the adjustment screw housing. If
the shutdown lever does not contact the
housing, loosen the fuel solenoid jam nut.
Turn the fuel solenoid plunger to extend
the linkage until lever contacts housing.
Tighten jam nut.
2
6
7
4
Verify fuel solenoid block pin does not disengage from the shutdown lever. If block
pin disengages from shutdown lever,
loosen the jam nut and turn the fuel solenoid plunger to bring the pin closer to the
shutdown lever. Tighten jam nut.
Check Solenoid Movement
5
3
Turn Engine Control switch to Off position.
Manually move shutdown lever and verify
solenoid plunger and linkage moves
freely. If linkage binds, loosen fuel
solenoid mounting screws and adjust
alignment so linkage moves freely
between the engine Run and Off positions.
Tools Needed:
3/8, 7/16 in.
10, 14 mm
Ref. 259 852
OM-258413 Page 42
. Complete Parts List is available at www.MillerWelds.com
C. Checking Throttle Solenoid
!
Stop engine.
If the engine does not stay at idle
speed, verify the the throttle solenoid
and linkage is installed properly.
Adjusting Throttle Solenoid
1
2
3
1
2
3
4
5
6
7
5
Throttle Solenoid
Jam Nut
Solenoid Link
Shoulder Bolt
Throttle Lever
Solenoid Rod
Throttle Solenoid Mounting
Screw
Loosen jam nut, remove shoulder
bolt, and remove link from throttle
lever. Install link 5/8 in. (16 mm) on
solenoid rod. Reconnect link to
shoulder bolt and throttle lever.
4
6
Push solenoid rod into idle (energized) position and check for nonbinding lateral movement of throttle
link at throttle lever. If link binds, loosen solenoid mounting screws. Move
the solenoid slightly until the link
moves freely with solenoid in deenergize (relaxed) and energized
positions. Tighten screws.
Tighten jam nut.
Go to Step D.
5/8 in.
(16 mm)
Tools Needed:
3/8, 7/16 in.
7
Check for non-binding
movement of link with solenoid in energized position.
5/32 in.
Check for non-binding
movement of link with
solenoid in deenergized
(relaxed) position.
259 852-A
OM-258413 Page 43
. Complete Parts List is available at www.MillerWelds.com
D. Making Engine Speed Adjustments
!
Perform engine speed adjustments
only through side door.
. Before adjusting engine speed, verify
throttle solenoid is installed properly
(see Section C on previous page).
Check engine speeds with a tachometer
or frequency meter (see Maintenance Label). If necessary, adjust speeds as follows:
Start engine and run until warm. Turn V/A
control to max.
Adjusting Idle Speed
Turn Engine Control switch to Run/Idle position to energize throttle solenoid.
1
2
3
4
5
Throttle Solenoid
Idle Speed Jam Nut
Plunger
Throttle Link
Throttle Lever
Loosen jam nut. While holding throttle link
with a 3/8 in. wrench, turn plunger clockwise to increase idle speed or counterclockwise to decrease idle speed.
To prevent binding,
be sure throttle link
is parallel with
throttle lever.
Tighten jam nut.
. After adjusting idle speed, verify the
throttle link is parallel with the throttle
lever. If necessary, rotate plunger to
align throttle link.
6
. Do not twist solenoid boot while ad-
7
justing engine speed.
Adjusting Weld/Power Speed
1
3
2
4
5
Start engine and run until warm. Turn V/A
control to max. Turn Engine Control switch
to Run position.
Do not twist
solenoid boot
while adjusting
engine speed.
6
7
High Speed Jam Nut
Adjustment Screw
Loosen nut and turn high speed adjustment screw counterclockwise to increase
speed. Turn screw clockwise to decrease
speed. Tighten jam nut.
Tools Needed:
3/8, 7/16 in.
10, 14 mm
259 852-A
OM-258413 Page 44
. Complete Parts List is available at www.MillerWelds.com
8-7. Troubleshooting Tables
A. Welding
Trouble
Low or no weld output; generator power output okay at AC receptacles.
Remedy
Check control settings.
Check weld connections.
Check fuse F1, and replace if open (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifiers SR2 and SR3,
and main rectifier SR1.
No weld output or generator power output at AC receptacles.
Be sure all equipment is disconnected from receptacles when starting unit.
Check fuses F1 and F2, and replace if open (see Section 8-4).
Check plug PLG6 connection.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
Low weld output.
Check control settings.
Check fuse F1, and replace if open (see Section 8-4).
Check engine speed, and adjust if necessary (see Section 8-6).
Replace air cleaner (see Section 8-2). Replace fuel filters (see Section 8-5).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
High weld output.
Check control settings.
Check engine speed, and adjust if necessary (see Section 8-6).
Erratic weld output.
Check control settings.
Tighten and clean connections to electrode and workpiece.
Use dry, properly stored electrodes for Stick and TIG welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welder/generator.
Check engine speed, and adjust if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
B. Generator Power
Trouble
No or low generator power output at
AC receptacles; weld output okay.
Remedy
Reset supplementary protectors (see Section 7-1).
Press GFCI receptacle Reset button (see Section 7-2).
Check fuse F2, and replace if open (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.
No generator power or weld output.
Be sure all equipment is disconnected from receptacles when starting unit.
Check fuses F1 and F2, and replace if open (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and
SR3.
Low power output at AC receptacles.
Increase Fine control R1 setting to max.
Check fuse F2, and replace if open (see Section 8-4).
High power output at AC receptacles.
Check engine speed, and adjust if necessary (see Section 8-6).
Erratic power output at AC receptacles.
Check fuel level.
Check engine speed, and adjust if necessary (see Section 8-6).
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes and slip rings.
OM-258413 Page 45
. Complete Parts List is available at www.MillerWelds.com
C. Engine
Maintenance Display
Action
noFUEL
Place Engine Control switch in the Off position, refuel, and start engine.
HI H2O
Coolant temperature is too high. Allow engine to cool and check coolant level (see Section 8-5).
LO OIL
Oil pressure is too low. Allow engine to cool and check oil level (see Section 8-5).
Wrench icon flashes.
Oil change is due.
Trouble
Engine does not crank.
Remedy
Supplementary protector CB8 may be open (see Section 8-4). Wait and retry.
Check battery voltage.
Check battery connections and tighten if necessary.
Check Engine Control switch to engine wiring harness connections.
Have Factory Authorized Service Agent check Engine Control switch S2 or circuit breaker CB8.
Engine cranks but does not start.
Check fault indicators on fuel gauge (see Section 6-1).
Check fuel level and fill tank with fresh fuel.
Glow plug circuit breaker CB7 may be open (see Section 8-4). Wait and retry.
Service inline fuel strainer and fuel filter (see Section 8-2).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Check fuel solenoid (see Section 8-6).
Have Factory Authorized Service Agent check glow Plug switch S6, glow plug, and control relay CR3.
Engine starts but stops when Engine
Control switch S2 returns to Run/Idle
position.
Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on
fuel gauge (see Section 6-1). Engine will not start if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
Engine stopped during normal
operation.
Check fuel level and fault indicators on fuel gauge (see Section 6-1). Check fuel for water or other
contaminants.
Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on
fuel gauge (see Section 6-1). Engine stops if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine does not return to idle speed
when load is removed with Engine
Control switch in Run/Idle position.
Remove all weld and generator power loads.
Check for obstructed movement of solenoid linkage (see Section 8-6).
Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, throttle
solenoid TS1, and Engine Control switch S2.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Check for obstructed movement of solenoid linkage (see Section 8-6).
Have Factory Authorized Service Agent check idle module PC1, control relay CR2, control relay CR4,
current transformer CT1, and throttle solenoid TS1.
OM-258413 Page 46
. Complete Parts List is available at www.MillerWelds.com
SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
....................
....................
....................
....................
....................
....................
. . . . . . . . GLOW PLUG .
....................
. . . . . . . . . F1, F2 . . .
....................
....................
....................
....................
259935
258349
213858
259934
187443
187459
187820
187819
169296
197145
280496
280837
230293
..
..
..
..
..
..
..
..
..
..
..
..
..
Filter Kit, Kubota (Includes air cleaner element, fuel, oil filters) . . . . . . . . .
Air Cleaner, Intake Dry Straight Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Fuel (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Pressure Oil 7psi Nc Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Temperature (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter, Engine Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
1
1
OM-258413 Page 47
SECTION 10 − ELECTRICAL DIAGRAMS
258 418-B
Figure 10-1. Circuit Diagram For Welder/Generator
OM-258413 Page 48
Notes
OM-258413 Page 49
SECTION 11 − 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.
11-1. 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 2018−06 − ST-800 577
11-2. 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-258413 Page 50
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.
11-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
GND/PE
3
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
11-4. 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 11-8).
VOLTS 115
AMPS 4.5
Hz
50/60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its
running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-258413 Page 51
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10,550
15,900
23,300
8100
23,300
35,000
46,700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10,700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
Farm Duty Motors Std. (e.g. Conveyors, Feed
Augers, Air Compressors)
Farm Duty Motors High Torque
(e.g. Barn Cleaners, Silo Unloaders, Silo Hoists,
Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-258413 Page 52
Rating
Starting Watts
Running Watts
2 HP
1/3 HP
1000
1650
3400
4400
2900
10,500
1720
1000
650
1000
1400
1100
2800
720
1/2 HP
2575
975
3/4 HP
4500
1400
1/4 HP
1/2 HP
3/4 HP
1 HP
6100
1600
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
8200
10,550
15,900
23,300
8100
2200
2850
3900
6800
2000
6000
5 HP
23,300
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
1/2 HP
500 PSI
550 PSI
700 PSI
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
950
1400
1600
800
750
1000
800
1050
1/3 HP
1/2 HP
1/3 HP
1/2 HP
11-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in.
3/8 in.
1/2 in.
6-1/2 in.
7-1/4 in.
8-1/4 in.
9 in.
10 in.
14 in.
6 in.
8 in.
10 in.
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in.
2 HP, 14 in.
Standard 9 in.
Heavy Duty 12 in.
1/3 HP
18 in.
HID
Metal Halide
Mercury
Sodium
Vapor
400 GPH
900 GPH
3/4 HP, 16 in.
1 HP, 20 in.
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10,500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-258413 Page 53
11-8. 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
11-9. 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-258413 Page 54
11-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
4
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s
Manual and national, state,
and local codes.
!
Do not connect to any electrical distribution system
normally supplied by utility
power unless a proper transfer switch and grounding
procedure are employed.
. Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
1 Utility Electrical Service
Essential
Loads
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (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 11-4).
OM-258413 Page 55
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4 (25)
6 (16)
8 (10)
10 (6)
12 (4)
14 (2.5)
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4 (25)
8 (10)
10 (6)
12 (4)
14 (2.5)
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-258413 Page 56
6 (16)
SECTION 12 − STICK WELDING (SMAW) GUIDELINES
12-1. Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
Constant Current
Welding Power Source
Work Clamp
Place as close to the weld as
possible.
3
Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Follow recommendations of the electrode manufacturer when setting
weld amperage (see Section
12-2).
5
4
2
3
6
1
7
4
Insulated Electrode Holder
5
Electrode Holder Position
6
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode diameter. Examine the weld bead to
determine if the arc length is correct.
Arc length for 1/16 and 3/32 in. diameter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
stick 2018-01 − 151593
OM-258413 Page 57
7014
7018
7024
Ni-Cl
308L
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DEEP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
FLAT
HORIZ*
LOW
SMOOTH, EASY,
FASTER
NI-CL
EP
ALL
LOW
CAST IRON
308L
EP
ALL
LOW
STAINLESS
USAGE
ALL
EP
AC
EP
6011
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
PENETRATION
6013
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
12-2. Electrode And Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
12-3. Striking An Arc
1
!
Weld current starts when electrode touches workpiece.
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
2
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out,
electrode was lifted too high. If electrode sticks to workpiece, use a quick
twist to free it.
Tapping Technique
3
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
1
2
3
S-0049 / S-0050
OM-258413 Page 58
12-4. Positioning Electrode Holder
1
2
End View Of Work Angle
Side View Of Electrode
Angle
After learning to start and hold
an arc, practice running beads
of weld metal on flat plates using
a full electrode.
1
10°-30°
90°
Hold the electrode nearly perpendicular to the work, although
tilting it ahead (in the direction of
travel) will be helpful.
2
90°
. To produce the best results,
hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
constant rate as it melts.
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
12-5. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
12-6. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-258413 Page 59
12-7. Conditions That Affect Weld Bead Shape
. Weld bead shape is affected
by electrode angle, arc length,
travel speed, and thickness of
base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
12-8. Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a
wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of
electrode.
S-0054-A
12-9. Welding Lap Joints
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
30°
Or Less
30°
Or Less
1
1
2
3
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
S-0063 / S-0064
OM-258413 Page 60
12-10. Welding Groove (Butt) Joints
1
Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
One side of a metal plate will curl
up toward the weld. Distortion will
also cause the edges of a butt joint
to pull together ahead of the electrode as the weld cools.
1
2
2
1/16 in.
(1.6 mm)
Single V-Groove Weld
4
Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
ensure good welds.
30°
The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on materials up to 3/4 in. (19 mm) thick
and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
Square Groove Weld
3
S-0062
12-11. Welding T-Joints
1
2
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
3
1
2
45°
Or
Less
1
2
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
12-8. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
OM-258413 Page 61
12-12. Weld Test
1
2
3
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
probably too long.
3
If the weld contains bits of slag, the arc may have been
too long or the electrode was moved incorrectly which
allowed molten slag to be trapped in the weld. This may
happen on a V-groove joint made in several layers and
calls for additional cleaning between layers.
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
Vise
Weld Joint
Hammer
2
1
2 To 3 in.
(51-76 mm)
2
1
If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed.
S-0057-B
12-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
OM-258413 Page 62
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-258413 Page 63
SECTION 13 − GMAW WELDING (MIG) GUIDELINES WHEN
USING A VOLTAGE-SENSING FEEDER
13-1. Typical GMAW (MIG) Process Connections Using A Voltage-Sensing Wire Feeder
!
Weld current can damage
electronic parts in vehicles. Disconnect both
battery cables before welding on a vehicle. Place work
clamp as close to the weld
as possible.
Voltage sensing wire feeders are
used with constant current (CC)
or constant voltage (CV) power
sources (14 pin receptacle not required).
Constant
Current (CC)
Or Constant
Voltage (CV)
Welding
Power Source
If using a CC or CV welding power
source without a weld output contactor, use optional secondary
contactor.
. For GMAW, use optional gas
valve.
Gun
Voltage
Sensing Wire
Feeder
Workpiece
Work Clamp
Electrode Lead
Voltage
Sensing Clamp
Work Lead
GMAW2 2018−12 (Voltage Sens) − 802 488
13-2. Holding And Positioning Welding Gun
. Welding
wire is energized
when gun trigger is pressed.
Before lowering helmet and
pressing trigger, be sure wire is
no more than 1/2 in. (13 mm)
past end of nozzle, and tip of
wire is positioned correctly on
seam.
1
1
3
2
2
3
4
5
5
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
1/4 to 1/2 in. (6 To 13 mm)
Cradle Gun and Rest Hand on
Workpiece
4
0°-15°
90°
90°
0°-15°
45°
45°
End View Of Work Angle
Side View Of Gun Angle
Groove Welds
End View Of Work Angle
Side View Of Gun Angle
Fillet Welds
S-0421-A
OM-258413 Page 64
13-3. Conditions That Affect Weld Bead Shape
. Weld bead shape depends on
gun angle, direction of travel,
electrode extension (stickout),
travel speed, thickness of
base metal, wire feed speed
(weld current), and voltage.
10°
Push
10°
Perpendicular
Gun Angles And Weld Bead Profiles
Short
Drag
Normal
Long
Electrode Extensions (Stickout)
Short
Normal
Long
Fillet Weld Electrode Extensions (Stickout)
Slow
Normal
Fast
Gun Travel Speed
S-0634
OM-258413 Page 65
13-4. Gun Movement During Welding
. Normally,
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads works better.
1
1
2
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
3
S-0054-A
13-5. Poor Weld Bead Characteristics
1
2
3
4
5
1
2
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
3
5
S-0053-A
13-6. Good Weld Bead Characteristics
1
2
3
1
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
2
3
4
5
OM-258413 Page 66
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
No Overlap
Good Penetration into Base
Metal
13-7. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
13-8. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
13-9. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-258413 Page 67
13-10. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
13-11. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
13-12. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-258413 Page 68
13-13. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
13-14. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
Notes
OM-258413 Page 69
13-15. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed
over the years. The most commonly used shielding gases are listed in the following table.
Application
Gas
Spray Arc
Steel
Short
Circuiting
Steel
Spray Arc
Stainless
Steel
Short
Circuiting
Stainless
Steel
GMAW-P
Stainless
Steel
All
Positions
Argon
Argon + 1% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 2% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 5%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 10%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 25%
CO2
All
Positions
Argon + 50%
CO2
All
Positions
CO2
All
Positions
Spray Arc
Aluminum
Short
Circuiting
Aluminum
GMAW-P
Aluminum
All
Positions
All
Positions
All
Positions
All
Positions
Helium
All
Positions1
Argon +
Helium
All
Positions1
90% HE +
7-1/2% AR +
2-1/2% CO2
65% AR + 33%
HE + 2% CO2
1
GMAW-P
Steel
Heavy Thicknesses
OM-258413 Page 70
All
Positions
All
Positions
13-16.
Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Probable Cause
Wire feed motor operates, but Too little pressure on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls.
Wire curling up in front of the
wire feed rolls (bird nesting).
Wire feeds, but no gas flows
(GMAW).
Remedy
Increase pressure setting on wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high.
Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly.
Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Too much pressure on wire feed rolls.
Decrease pressure setting on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner.
Replace liner.
Gas cylinder empty.
Replace empty gas cylinder.
Gas nozzle plugged.
Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted.
Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid.
Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source.
for correct voltage.
Welding arc not stable.
Wire slipping in drive rolls.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-258413 Page 71
Notes
Notes
Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
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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.
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* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01
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