Miller | MK071019R | Owner Manual | Miller ENPAK A30 GBW DIESEL User manual

Miller ENPAK A30 GBW DIESEL User manual
OM-281718B
)
2019−02
Processes
Battery Charging
Multiprocess Welding
Description
Engine Driven Air Compressor,
Generator, Battery Charger, Chassis
Power, And Welder
)
EnPak A30 Diesel
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com/EnPak
File: Engine Drive
From Miller to You
Thank you and congratulations on choosing EnPak® by Miller. Now
you can get the job done and get it done right. We know you don’t have
time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com/EnPak on the web.
EnPak_Thank 2017−06
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. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Power And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Weld Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Base Unit Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote Panel Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Volt-Ampere Curves - Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Volt-Ampere Curves - Battery Charge And Chassis Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Weld/Battery Charge Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Installing Optional Auxiliary Power Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Electrical Connections For Remote Panels And Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Auxiliary Power Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Grounding Generator And Remote Panel To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Air Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
6
6
6
7
7
7
9
10
11
13
13
13
14
14
14
16
16
16
16
16
16
16
17
17
18
19
20
21
22
23
23
24
25
26
27
28
29
29
30
31
WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or
other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
TABLE OF CONTENTS
5-11. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting External Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Process Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Auto Start/Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − COMPRESSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Air Compressor Switch And Adjusting System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Air Compressor Operation With Air Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − CHASSIS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Chassis Power And Auto Start/Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Battery Charging Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Connecting Uninstalled Battery To Battery Charge Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Connecting Installed Battery To Battery Charge Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Setting Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Setting Battery Jump/Crank Assist Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Battery Charging Information On Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
SECTION 11 − WELDING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Weld Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-5. Stick Scratch Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-6. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-7. MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-8. Connecting Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − CAN-BUS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. CAN-Bus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. EnPak A30 J1939 Messages Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Changing Compressor Oil, Oil Filter, Air Cleaner, And Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . .
13-4. Replacing Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-5. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-6. Changing Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-8. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 16 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
32
33
34
34
35
36
37
38
39
40
41
41
42
43
44
44
45
45
45
46
47
47
48
49
49
49
50
51
51
51
52
53
53
54
55
56
57
57
57
60
60
61
62
63
64
65
66
67
68
72
72
74
78
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.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding
procedure are employed.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Manual before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-281718 Page 1
FLYING METAL or DIRT can injure
eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND
hazardous.
GASES
can
be
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
OM-281718 Page 2
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-281718 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Use only equipment suitable for operation on 60 or 50/60 Hz
power.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use correct procedures and equipment of adequate capacity to
lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-281718 Page 4
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
Have only qualified persons do battery charging work.
If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc,
make sure all accessories are off.
Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
Do not charge a frozen battery.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
HIGH PRESSURE FLUIDS can injure or kill.
Engine fuel system components can be under
high pressure.
Before working on fuel system, turn off engine
to release pressure.
If any fluid is injected into the skin or body seek medical help immediately.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with electronic equipment
perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-281718 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
Always start and operate the engine in a well−ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
For Standards regulating hydraulic systems, contact the National Fluid
Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
WI 53214 (phone: (414) 778-3344, website: www.nfpa.com).
Battery Service Manual, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.batterycouncil.org).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-281718 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.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
d’une tension de circuit−ouvert double.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
OM-281718 Page 7
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Arrêtez le moteur sur l’onduleur et déchargez les condensateurs
d’entrée conformément aux instructions du manuel avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en fil
de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
OM-281718 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).
Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
recouvrements et dispositifs de protection.
panneaux,
Arrêter le moteur avant d’installer ou brancher l’appareil.
Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-281718 Page 9
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes
industrielles et aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident matériel
ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air comprimé.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
OM-281718 Page 10
MÉTAL CHAUD provenant du découpage
ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
comprimé, les branchements et les flexibles en recherchant tout
signe de détérioration, de fuite et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES
PIÈCES
CHAUDES
peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement avant
d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Utiliser uniquement des équipements adéquats pour un fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-281718 Page 11
LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les
modèles.
Toujours porter une protection faciale, des gants en caoutchouc
et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles de
batterie, des câbles de chargeur de batterie (le cas échéant) ou de
batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si
l’appareil dispose d’une fonctionnalité de charge de batterie destinée à
cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres sources
d’inflammation doivent être maintenues à l’écart des batteries. Ces
dernières produisent des gaz explosifs en fonctionnement normal et
en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations sur
une batterie ou à proximité de celle−ci. Voir le manuel de service de
batterie (indiqué dans Normes de sécurité) pour plus d’informations.
Les opérations de charge de batterie ne doivent être effectuées que
par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge, débrancher
tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour
éviter un arc, s’assurer que tous les accessoires sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur
de batterie pour alimenter un autre circuit électrique basse tension ou
pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en l’absence
d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge ne
se touchent pas.
Ranger les câbles de charge à distance du capot, des portes et des
pièces mobiles du véhicule.
LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.
Les composants du système d’alimentation
peuvent contenir du carburant sous pression
élevée.
Avant d’intervenir sur le système d’alimentation de carburant,
arrêter le moteur pour dépressuriser le système.
En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
OM-281718 Page 12
Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles
que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation
de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Pour les moteurs diesel :
AVERTISSEMENT : les gaz d’échappement de moteurs diesel
vous exposent à des produits chimiques, reconnus par l’État
de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
Si la zone est fermée, diriger l’échappement vers l’extérieur.
Ne pas modifier ni altérer le système d’échappement.
Ne pas faire tourner le moteur au ralenti, sauf si nécessaire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West
Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
778-3344, site web : www.nfpa.com).
Manuel de service de batterie, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
1-312-245-1074, site Web : www.batterycouncil.org).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: par exemple, des restrictions
d’accès pour les passants ou une évaluation individuelle des risques
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-281718 Page 13
A 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
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
Hot muffler and exhaust pipe can cause severe burns.
Safe90 2017−04
Recycle.
Safe103 2012−09
3-2. Miscellaneous Symbol Definitions
Amperage
Internal Protection
Rating
Negative
Single Phase
Alternator
Positive
Engine−Driven
Generator with
Rectifier
Voltage
Hertz
Rated No−Load
Voltage (OCV)
Load Voltage
Rated Welding
Current
Duty Cycle
Direct Current
(DC)
Alternating
Current (AC)
Protective Earth
(Ground)
OM-281718 Page 14
Output
Remote
Read Operator’s
Manual
Circuit Breaker
Welding (General)
Off
Percent
On
A complete Parts List is available at www.MillerWelds.com
Shielded Metal
Arc Welding
(SMAW)
Engine
Glow Plug
Gas Metal Arc
Welding (GMAW)
Engine
Belt Drive
Engine Start
Engine Coolant
Temperature
Flux Cored Arc
Welding (FCAW)
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Touch Start
(GTAW)
(Engine RPM)
Engine Stop
Check Valve
Clearance
Idle
(Slow)
Arc Control
Run
(Fast)
USB
Temperature
Air Compressor
Push Button
Engine Oil
Air Filter
Fuel
Rotating Knob
And Push Button
Battery (Engine)
OM-281718 Page 15
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front and side panels. Use rating label to determine rated output. For future
reference, write serial number in space provided on back cover of this manual.
4-2. Air Compressor Specifications
Compressor
Type
Air Output At Effective
Working Pressure
Pressure
Rotary Screw
30 scfm @ 175 psi
100% Duty Cycle, 3600 RPM
32 CFM Max. Flow
Range: 80 −175 psi
(552−1206 kPa)
Safety Relief
Valve Setting
Air Compressor
Oil Capacity
Auto Shutoff: 200 psi
(1379 kPa)
Pressure Relief: 220 psi
(1517 kPa)
2 qt (1.89 L)
4-3. Battery Charger Specifications
Output
Rated Output
Output Range
Up to 100 A, 12 V Charge
Battery Charge
Output Voltage
0 - 100 A
Up to 100 A, 24 V Charge
12 or 24 V
Crank Assist
300 A, 12 V for 20 seconds
0 - 300 A
300 A, 24 V for 20 seconds
Chassis Power
100 A, 12 V, Continuous
0 - 100 A
12 V Only
4-4. Power And Engine Specifications
Generator Power Rating
Engine
Continuous: 6.5 kVA/kW, 54/27 A,
120/240 V AC, 60 Hz, Single-Phase
D722 Kubota, Three-Cylinder, 20 HP Diesel Engine w/Electronic
Governor, Auto Glow Plugs, And 60A Alternator
Peak: 8.0 kVA/kW
4-5. Weld Specifications
This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Welding Mode
Rated Welding Output
Maximum Weld OpenCircuit Voltage
Weld Output Range
58 Volts
30 − 210 A
58 Volts
30 − 210 A
58 Volts
30 − 220 A
210 A, 18.4 V, 20% Duty Cycle
CC/DC TIG
140 A, 15.6 V, 60% Duty Cycle
120 A, 14.8 V, 100% Duty Cycle
210 A, 28.4 V, 20% Duty Cycle
CC/DC Stick
140 A, 25.6 V, 60% Duty Cycle
120 A, 24.8 V, 100% Duty Cycle
210 A, 24.5 V, 20% Duty Cycle
CV/DC MIG
140 A, 21.0 V, 60% Duty Cycle
120 A, 20 V, 100% Duty Cycle
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use.
IP23 2017−02
OM-281718 Page 16
A complete Parts List is available at www.MillerWelds.com
B. 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
4-7. Base Unit Dimensions, Weights, And Operating Angles
Dimensions
28.86 in. (733 mm)
Height
29.78 in. (756 mm) with
exhaust pipe
Width
20.25 in. (514 mm)
Depth
44.61 in. (1133 mm)
A
20 in. (508 mm)
B
21.77 in. (553 mm)
C
0.88 in. (22 mm)
D
6.13 in. (156 mm)
E
29.86 in. (758 mm)
F
44 in. (1118 mm)
G
9/16 in. (14 mm) Dia.
H
22.73 in. (577 mm)
D
G
4 Holes
!
Do not exceed tilt angles or engine could be
damaged or unit could tip.
!
Do not move or operate unit where it could tip.
!
Do not operate suspended from lifting eye.
F
E
20°
C
20°
20°
Weight
571 lb (259 kg)
A
Lifting Eye Weight Rating
B
1000 lb (453 kg)
H
20°
907759
Internal Mounting Hole Dimensions
A
0.5 in. (12.7 mm) dia.
(4 holes) for optional internal
mounting
Bottom Of Unit
B
B
27.48 in. (698 mm)
A
C
8.88 in. (226 mm)
C
D
17 in. (432 mm)
D
277870
4-8. Remote Panel Dimensions And Weights
Remote Control Panel
Weld/Battery Charge Remote Panel
Optional Auxiliary Power Remote Panel
Height
6.195 in. (157 mm)
6.768 in. (172 mm)
6.57 in. (167 mm)
Width
16.24 in. (412 mm)
9.615 in. (244 mm)
10.24 in. (260 mm)
Depth
4.276 in. (109 mm)
4.978 in. (126 mm)
4.524 in. (115 mm)
Weight
6 lb (2.72 kg)
(includes 20 ft cable)
31 lb (14.06 kg)
(includes 30 ft cables)
16 lb (7.26 kg)
(includes 30 ft cables)
OM-281718 Page 17
A complete Parts List is available at www.MillerWelds.com
4-9. Duty Cycle And Overheating
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
This unit is rated for welding at
120 amperes continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Weld Duty Cycle (%)
100
80
60
40
20
0
0
50
100
150
200
250
Weld Amps
20%Duty Cycle at 200 amperes DC
2 Minutes Welding
8 Minutes Resting
100% Duty Cycle at 120 Amperes DC
60% Duty Cycle at 140 Amperes DC
6 Minutes Welding
4 Minutes Resting
Continuous Welding
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
281705
OM-281718 Page 18
A complete Parts List is available at www.MillerWelds.com
4-10. Generator Power Curves
The AC generator power curve
shows the generator power available
in amperes at the receptacles.
120 Volt
Tools and motors are designed to operate within 10% of 120/240 VAC.
140
120
100
Volts
80
60
40
20
0
0
10
20
30
40
50
30
40
50
Amps
240 Volt
280
240
200
160
Volts
120
80
40
0
0
10
20
Amps
281704
OM-281718 Page 19
A complete Parts List is available at www.MillerWelds.com
4-11. Volt-Ampere Curves - Weld
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the unit. Curves of other settings fall
between the curves shown.
Stick
45
40
35
30
VOLTS
25
20
15
10
MAX
MID
MIN
5
0
0
50
100
150
AMPS
200
250
300
350
MIG
60
50
40
VOLTS
30
MAX
MID
20
MIN
10
0
0
50
100
150
200
250
AMPS
281702
OM-281718 Page 20
A complete Parts List is available at www.MillerWelds.com
4-12. Volt-Ampere Curves - Battery Charge And Chassis Power
12 Volts
18
16
14
12
10
Volts
8
6
4
2
0
0
50
100
150
200
250
300
200
250
300
350
Amps
24 Volts
35
30
25
20
Volts
15
10
5
0
0
50
100
150
350
Amps
Chassis Power
16
14
12
10
Volts
8
6
4
2
0
0
20
40
60
Amps
80
100
120
281703 / 284438
OM-281718 Page 21
A complete Parts List is available at www.MillerWelds.com
4-13. Fuel Consumption
Fuel Consumption (gal/hr)
Air Compressor
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
0%
20%
40%
60%
80%
100%
Air Compressor Duty Cycle (%) at 150psi/30 CFM/3600 rpm
Auxiliary Power
Fuel Consumption (gal/hr)
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0
1
2
3
4
Aux Power (kW)
5
6
7
Welding
Fuel Consumption (gal/hr)
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
0
50
100
150
Welding Amperage (A) at Rated Output
OM-281718 Page 22
200
250
281701
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Unit
Movement / Airflow Clearance
24 in.
(610 mm)
2 in.
(51 mm)
1 in.
(25 mm)
OR
6 in.
(152 mm)
18 in.
(460 mm)
Location / Mounting
2
Welding Unit In Place
Bolting Unit In Place
3
2
OR
4
1
1
Install4_2019−02 − Ref. 907705 / 805454
Go
to MillerWelds.com for more
information on truck installations.
Movement
!
Do not move or operate unit where
it could tip.
!
Do not lift unit from end.
See Section 4-7 for lifting eye rating.
Airflow Clearance
NOTICE − Do not install unit where air flow
is restricted or engine may overheat.
Location/Mounting
!
Always securely fasten unit onto
transport vehicle and comply with
all DOT and other applicable codes.
!
Do not weld on base. Welding on
base can cause fuel tank fire or explosion.
NOTICE − Do not mount unit by supporting
the base only at the four mounting brackets. Do not use flexible mounts. Use crosssupports to adequately support unit and
prevent damage to base.
1 Cross-Supports (Minimum 3 in.
Wide)
2 Mounting Brackets (Supplied)
NOTICE − If mounting brackets are removed, the bolts must be reinstalled into
the unit.
Mount unit on flat surface or use crosssupports to support base. Secure unit with
mounting brackets or through internal
holes.
3
3/8 in. Bolt And Washer (Minimum −
Not Supplied)
4 3/8-16 x 1 in. Screws (Supplied)
To Bolt Unit In Place Using Internal
Pattern:
Remove hardware securing the four
mounting brackets to the base. Discard
brackets and reinstall original hardware.
Mount unit to truck with 3/8 in. (10 mm) or
larger hardware (not supplied).
To Weld Unit In Place:
Remove hardware securing the four
mounting brackets to the base. Reverse
brackets and reattach to base with original
hardware.
Weld unit to vehicle only at the four mounting brackets.
OM-281718 Page 23
A complete Parts List is available at www.MillerWelds.com
5-2. Installing Remote Control Panel
1
2
3
4
5
1
Remote Control Panel - Front
Mounting Hole (4)
Block-off Plate
12-Pin Connector
Remote Control Panel - Rear
Select mounting location and mark remote mounting hole placement. Ensure cables will reach from base unit to
remote. Mount rear panel by installing
bolts through four mounting holes.
Hardware is customer supplied.
Connector and cable may be routed
through rear of panel instead of
through the bottom. Supplied cable is
20 ft (6 m) long. If longer cable is needed, see product accessories for cable
extensions. To change the configuration, follow these steps:
Remove front panel.
5
2
Rear View
Remove 12-pin connector from front
cover by removing four mounting
bolts.
Remove block-off plate from rear panel by removing two mounting nuts.
15 in.
(381 mm)
Reinstall block-off plate in front panel
using existing hardware.
Reinstall 12-pin connector in rear panel using existing hardware.
3 in. (76.2 mm)
Reassemble front panel to rear panel.
4
3
5
Tools Needed:
Optional rear cable
exit shown.
3/8 in.
301510 / 284174
OM-281718 Page 24
A complete Parts List is available at www.MillerWelds.com
5-3. Installing Weld/Battery Charge Remote Panel
1
Weld/Battery Charge Remote
Panel - Front
2 Weld/Battery Charge Remote
Panel - Rear
3 Mounting Holes
4 Strain Relief
5 Weld Negative Cable
6 Weld Positive Cable
7 Battery Charge Cable
8 Plug
9 Outer Strain Relief Nut
10 Ground Stud
1
2
3
Select mounting location and mark remote mounting hole placement. Ensure cables will reach from base unit to
remote. Mount rear panel by installing
bolts through four mounting holes.
Hardware is customer supplied.
Rear View
7-5/8 in.
(194 mm)
8
3 in. (76.2 mm)
Strain relief and cables may be routed
through rear of panel or through the
bottom. To change the configuration,
follow these steps:
Remove front cover.
Remove weld positive and weld negative leads from weld terminals.
11 Retention Clip
4
10
9
5
6
7
Remove battery positive lead from battery charge terminal. To remove lead,
push down on metal retention clip in
plastic housing with a screwdriver and
pull lead out from backside.
Remove leads from strain reliefs by removing outer strain relief nut.
Remove plugs from back holes. Remove strain reliefs from bottom of remote box.
Install strain reliefs on back holes of remote box.
Install plugs in holes on bottom of remote front panel.
Route leads through strain relief and
reconnect to weld terminals and battery charge terminal. When reinstalling
battery positive lead, push lead in until
it clips on metal retention clip in plastic
housing.
Verify cable insulation extends
through strain relief. Then tighten outer
strain relief nut until cable does not
move in strain relief.
5
6
7
Optional rear cable
Reassemble front panel to rear panel.
exit shown.
11
Tools Needed:
3/8 in.
284274
OM-281718 Page 25
A complete Parts List is available at www.MillerWelds.com
5-4. Installing Optional Auxiliary Power Remote Panel
1
Auxiliary Power Remote PanelFront
2 Auxiliary Power Remote Panel Rear
3 Mounting Holes
4 Strain Relief
5 Plug
6 Ground Stud
7 Black Lead
8 Brown Lead
9 Blue Lead
10 Green Lead
11 Outer Strain Relief Nut
1
Remove front cover of remote panel.
Mount panel by installing bolts through
four mounting holes. Hardware is customer supplied.
3
2
Strain relief and cable may be routed
through rear of panel instead of through
the bottom. To change the configuration,
follow these steps:
Remove front cover.
7-5/8 in.
(194 mm)
Remove brown and black leads from the
circuit breakers. Remove the blue lead
from the 120 V receptacle. Remove the
green ground lead from the ground stud.
3 in. (76.2 mm)
Remove leads from strain relief by removing outer strain relief nut.
Remove plug from back hole. Remove
strain relief from bottom of remote box.
Install strain relief in back hole of remote
box.
Install plug in bottom hole of remote.
5
6
4
Route leads through strain relief and reconnect according to the diagram shown
below. Verify cable insulation extends
through strain relief. Then tighten outer
strain relief nut until cable does not move
in strain relief.
9
7
8
10
Optional rear cable
exit shown.
11
301511 / 284174
OM-281718 Page 26
A complete Parts List is available at www.MillerWelds.com
5-5. Electrical Connections For Remote Panels And Truck
Tools Needed:
3/8 in., 11/16 in.
Low Voltage DC Terminal Strip
1
2
3
4
10
11
9
5
6
7
8
282903 / 907759
!
Only qualified individuals should
make connections or crimp cables.
Cables are customer supplied.
1
2
3
4
5
6
Battery Charge Positive (2 AWG Min.)
Weld Positive (2 AWG Min.)
Weld/Battery Charge Negative (2
AWG Min.)
Vehicle Battery Positive (1/0 AWG
Min.)
Vehicle Battery Negative (1/0 AWG
Min.)
Vehicle Battery Negative (12 AWG
Min.)- Must Be Connected Directly To
Vehicle Battery
7 Vehicle Battery Positive (12 AWG
Min.)- Must Be Connected Directly To
Vehicle Battery
8 12 Volt Unit Enable Vehicle Safety
Interlock (16 AWG Min.)
9 Slide Clamp
10 10-Pin Spool Gun Connection
11 12-Pin Connection For Remote Panel
Connect 12-pin plug from remote panel to
12-pin receptacle on base unit.
Open compressor side door.
Remove electrical guard covering terminal
strip.
Route all weld/battery charge leads through
slide clamp into base of unit from either end.
Secure leads to low voltage DC terminal
strip studs.
Close slide clamps on both ends of base
unit.
Reinstall electrical guard covering terminal
strip. Close compressor side door.
For 12 volt circuit protection, install a 150
amp circuit breaker in vehicle positive line
as close to vehicle battery as possible.
OM-281718 Page 27
A complete Parts List is available at www.MillerWelds.com
5-6. Auxiliary Power Terminal Strip
1
High Voltage AC Terminal Strip
Black
Brown
Blue
3
Green
2
907759 / 282903-A
!
Only qualified individuals should
make connections or crimp cables.
Remove electrical guard covering terminal
strip.
1
AC Terminal Strip
2
Slide Clamp
Route all leads through slide clamp into
base of unit from either end.
3
Cable Clamps
Open compressor side door.
OM-281718 Page 28
Secure auxiliary power leads to AC terminal
strip. Reference label on electrical guard for
locating AC leads on terminal strip.
Secure auxiliary power cable using cable
clamps.
Close slide clamps on both ends of base
unit.
Reinstall electrical guard covering terminal
strip. Close compressor side door.
A complete Parts List is available at www.MillerWelds.com
5-7. Grounding Generator And Remote Panel To Truck Or Trailer Frame
1
2
GND/PE
3
Ref. rot_grnd3 2017−01 − 800 652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the unit
from the vehicle frame. Always con-
nect a ground wire from the generator equipment grounding terminal to
bare metal on the vehicle frame as
shown.
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
1
Equipment Grounding Terminal (On
High Voltage AC Terminal Strip; See
Section 5-6)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-8. Air Compressor Connections
Tools Needed:
!
Stop engine and wait for blow
down before servicing compressor.
!
Always put Engine Control
Switch in the Off position before
working on unit to prevent automatic starting.
7/8 in. (22 mm)
Depending on the desired compressed
air quality, air conditioning components
such as separators, filters, dryers, or air
reservoir may be required.
No check valve should be installed.
Obtain hoses of the proper length and
type with appropriate fittings for the installation.
Hose ID: 0.5 in. (12.7 mm)
Minimum Working Pressure: 350 psi
(2.41 MPa)
Minimum Burst Pressure: 1400 psi (9.65
MPa)
1
2
Air Compressor Connection
Slide Clamp
Air compressor connection is JIC male
1/2 in. (-8). JIC to push-on hose fitting is
located in shipping bag.
Route hose through slide clamp on either front or rear of machine and up to
compressor connection.
1
2
For proper compressor operation, a minimum 10 gallon air reservoir is required.
Air reservoir is not supplied.
907759
OM-281718 Page 29
A complete Parts List is available at www.MillerWelds.com
5-9. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Follow run-in procedure in engine manual.
This unit has a low oil pressure
shutdown switch. However,
some conditions may cause engine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Check fuel level
on a cold engine before use each
day.
Engine Oil
NOTICE − Do not exceed the ”Full”
mark on the oil level dipstick. Engine
damage may occur if crankcase is
overfilled.
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Use remote panel meters to determine hours until next recommended
oil change. See Section 13-5 for oil
change and maintenance hours reset procedure.
Use
correct grade oil for cold
weather.
Oil Fill
Oil Check
Full
907759
OM-281718 Page 30
A complete Parts List is available at www.MillerWelds.com
5-10. Compressor Prestart Checks
Oil Fill/
Check
Use only Miller oil
276620.
High/Max
2
1
Low/Min
Bottom
of oil sight
glass is minimum oil
level. Top of oil sight
glass is full.
907759
The compressor is equipped with high
Check all fluids daily. Compressor must
be cold and on a level surface. Unit is
shipped with oil.
Open side service door.
1 Oil Level Sight Glass
The unit is shipped with oil in the compressor. Oil level sight glass shows oil level.
NOTICE − Do not mix oil types. Do not
overfill. Use only Miller oil 276620.
level. Top of oil sight glass is full.
Minimum oil level is half way up the oil fill
pipe. Maximum oil level is in threaded area
of oil fill pipe.
!
Do not open oil fill cap until unit is
off and pressure in the compressor
case has been released according
to Section 7-2. Do not open oil fill
cap while running.
oil temperature shutdown. High oil
temperature can be caused by low oil
or hot air recirculation.
Bottom of oil sight glass is minimum oil
Check level frequently. If oil needs to be
added, be sure unit is off and compressor
case pressure is released according to
Section 7-2 before removing fill cap.
2
Air Compressor Oil Fill Cap
Hand tighten oil fill cap. Using excess
force can damage o-ring.
Inspect compressor air cleaner element
and replace if dirty (see Section 13-3).
Close side service door.
OM-281718 Page 31
A complete Parts List is available at www.MillerWelds.com
5-11. Installing Exhaust Pipe
!
Stop engine and let cool.
!
Always put Engine Control
Switch in the Off position before working on unit to prevent
automatic starting.
!
Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep away
from exhaust outlet.
!
Do not point exhaust pipe toward any compressed gas
tank.
Point exhaust pipe in desired di-
rection but always away from
control panel and direction of
travel.
Install provided pipe and clamp onto
exhaust outlet and tighten.
Tools Needed:
1/2 in.
907759
Notes
OM-281718 Page 32
A complete Parts List is available at www.MillerWelds.com
5-12. Connecting External Fuel Supply
!
Route all hoses away from
hot, sharp or moving parts.
Check all connections and
hoses for damage, leaks, and
wear.
1
2
Check Valve
Electric Fuel Pump
1
When connecting to an external fuel supply, follow all applicable fuel
hose regulations.
To connect to an external fuel supply, disconnect factory hoses from
electric fuel pump and return check
valve. Use a 5/16 in. (7.94 mm) fuel
hose for fuel supply and a 3/16 in.
(4.76 mm) fuel hose for fuel return.
Connect supply hose to electric fuel
pump and return hose to check
valve.
Connect hoses and secure with
hose clamps. Use grommets if routing hoses through sheet metal.
2
Remove plugs in rear panel holes.
Install supplied bushings and route
fuel lines through access holes.
Onboard electric pump will prime
engine when engine is cranking.
Pump can lift fuel up to 10 feet (3 m).
Connect
fuel return
line to check valve.
Connect fuel supply line to barbed elbow on fuel pump.
Route
fuel
lines
through access holes
in rear panel.
Tools Needed:
907759
OM-281718 Page 33
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − CONTROLS
6-1. Control Panel
12
9
7
11
5
10
6
2
4
3
1
8
Ref. 281316
Engine Starting Controls
Push the control to use as Select button.
1
To access Arc Control setting, push and
Engine Control Switch
Use switch to start engine, select speed
mode, and stop engine. In Auto Speed position, engine runs at appropriate speed according to load. In Auto Start/Stop position,
engine stops when not in use and restarts
with compressor load or low battery voltage
(see Section 6-7).
To Start: Place switch in the Auto Speed position to allow the control system to initialize. All
LEDs and meter displays illuminate for several seconds. The display flashes “ENPK
A30D.” Turn switch to start position and release. The starting sequence begins automatically. “STARTING” is displayed on the
weld meter displays, and the beeper sounds
for five seconds, or longer if the glow plugs are
energized. The starter engages and cranks
the engine until it starts.
hold Adjust control for 1 second, then release. Rotate counterclockwise to set
softer arc control. Rotate clockwise to set
stiffer arc control. Push Adjust control in
and release to save Arc Control setting.
Arc Control setting will time out after 5
seconds of inactivity.
To access Service Menu, push and hold
Adjust control for 5 seconds, then release. See Section 6-3 for Service Menu
operation. Service Menu will time out after 5 seconds of inactivity.
Weld Meters
Weld meters also work in combination to
display troubleshooting error codes and
other mode dependent information.
To Stop: Turn engine control switch to OFF
position.
5
Engine Gauges, Meters, And Lights
2 Engine/Compressor Service Indicator
Lights
Notifies user that engine oil or compressor oil
service is due. The LEDs illuminate when oil
change hours are 0 or less.
For GMAW and FCAW welding, the voltmeter
display toggles between preset voltage and
actual voltage. Voltmeter displays voltage at
the weld output terminals, but not necessarily
the welding arc due to resistance of cable and
connections.
DC Voltmeter
Weld Controls
3 Process Switch
See Section 6-2 for Process switch information. This switch works in conjunction with the
Charge/Weld switch.
To set voltage, turn Process switch to GMAW
or FCAW position. Turn V/A control until desired voltage is displayed on Voltmeter. When
welding is finished, voltmeter displays average weld voltage and then defaults to preset
voltage.
4
6
Adjust Control/Select Button
Adjust Control
With Process Switch in any SMAW or GTAW
process, turn Adjust control to adjust preset
amperage. With Process switch in any FCAW
or GMAW process, turn Adjust control to adjust preset voltage.
Select Button
OM-281718 Page 34
DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process switch to Stick
or TIG position. Turn V/A control until desired
amperage is displayed on Ammeter. When
welding is finished, ammeter displays aver-
age weld amperage and then defaults to preset amperage.
7 Arc Control Meter
Displays current Arc Control setting. Default
value for all processes is 0. Arc Control settings adjust DIG for SMAW and inductance
for FCAW and GMAW processes. Push and
hold Adjust Control/Select button for one second to adjust arc control. For softer settings,
the LEDs to the left of the star illuminate. For
stiffer settings, the LEDs to the right of the star
illuminate.
Other Receptacles
8 USB Receptacle
Allows software updates from a USB drive
(see Section 6-4). A summary file of recorded
data from the unit will be saved to a USB drive
that is inserted (see Section 6-5).
Indicator Lights
9 Setup Light
Illuminates when in the Service Menu.
10 Glow Light
Illuminates when the engine glow plugs are
energized.
Other Functions
11 Charge/Weld Switch
Place in the Charge position for battery
charge operation. Use the process switch to
select either 12 or 24 volt charge or chassis
power.
Place in the Weld position for welding operation. Use the process switch to select specific
weld process.
When in the Charge position, only battery
charge processes are selectable. When in
the Weld position, only weld processes are
selectable.
12 Compressor Switch
Use to control air compressor operation. See
Section 7.
A complete Parts List is available at www.MillerWelds.com
6-2. Process Switch
1
Process Switch
Process switch works in conjunction with Charge/Weld switch.
Charge/Weld switch must be
1
in the WELD position for weld
processes, and in the
CHARGE position for battery
charge operation.
Use switch to select weld process
and battery charge process (see
table below).
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Section 11-6).
See Section 9 for battery charge
operation.
See Section 8 for chassis power
operation.
Ref. 281606-A
BATTERY CHARGE
OUTPUT ON
Process Switch Setting
Typical Process Applications (DC Only)
Output On – GMAW/FCAW (MIG)
MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not
require a control cable back to the welder/generator.
Output On – FCAW-S (Electrode
Negative) No Gas
FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that
does not require a control cable back to the welder/generator.
Output On − SMAW (STICK XX18
and STICK XX10)
Stick welding. Strike an arc to start welding.
Output On – GTAW (Lift-Arc TIG)
Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
welder/generator to aid arc start.
Output On – Aluminum
Aluminum solid wire uses a remote connected spoolgun accessory.
Battery Charge 12V
Battery charging or jump starting with a 12 volt system.
Battery Charge 24V
Battery charging or jump starting with a 24 volt system.
Chassis Power
Powering large 12 volt loads on vehicle such as electric cranes, lights, or vehicle
systems.
OM-281718 Page 35
A complete Parts List is available at www.MillerWelds.com
6-3. Service Menu
1
Adjust Control/Select Button
Press and hold Adjust Control/Select
button for 5 seconds, then release to
access the Service Menu. Rotate the
knob to scroll through the menu
items. Press and release the control
to access the options and information within each menu item.
1
Rotate the control counterclockwise
to decrease the value. Rotate the
control clockwise to increase the value.
Press and release control to save selection. After 5 seconds of inactivity,
the menu will time out and the selection will be saved.
281316-A
Menu Item
Selectable Item
Option(s)
HOUR MTR
−−
ENG OIL
OIL HOUR
OIL SET
COMP OIL
Description
Displays the current Engine Hours.
Displays the current oil change countdown.
Sets the oil change interval.
OIL RSET
Resets the oil change countdown.
OIL HOUR
Displays the current oil change countdown.
OIL SET
OIL RSET
Sets the oil change interval.
Resets the oil change countdown.
RPM DISP
−−
Displays current engine RPM.
RPM SET
AUTO
Enables auto speed function.
3600
Locks engine speed at 3600 RPM.
STOP TIME
2 to 30 min
MIN PRES
90 psi up to 10 psi less than
max pressure
Unit idle time before auto stop (adjustable in 1 min increments).
Minimum pressure to start air compressor (adjustable in 1 psi increments).
MAX PRES
175 psi down to 10 psi
greater than min pressure
Maximum pressure to stop air compressor (adjustable in 1 psi increments).
SOFT WARE
−−
FACT RSET
RSET YES
Resets all settings to factory defaults.
RSET NO
All settings remain at previous settings.
OM-281718 Page 36
Displays the current revision of firmware installed.
A complete Parts List is available at www.MillerWelds.com
6-4. Updating Software
1
Obtain the latest software to be loaded
from MillerWelds.com.
Copy the desired software to an approved
USB flash drive (see Section 14-1).
1 Adjust Control/Select Button
With the machine turned off, insert the
flash drive into the USB receptacle on the
front of the machine. Turn the Engine Control switch to the Auto-Speed or Auto Start/
Stop position.
Do not start the engine.
When the machine has powered up, if valid
files exist on the flash drive, the user is
prompted to confirm the start of the download. The Voltmeter/Ammeter display
reads: AL? NO.
Confirm by rotating the Adjust Control/Select button clockwise to select YES. Then
press the Select button.
After the update has started, do not
power down or remove the flash drive
until the update is complete.
During the download, the left meter display
indicates the active download with AL U,
AP U, AL C, and AP C. The right meter display indicates the percentage of the download completed with a number from 0 to
100. Software updates may take several
minutes.
If a valid update file for the weld module is
detected, the meter display reads AL
STRT to instruct the user to start the engine. Do not power down the unit. Turn the
engine control switch to start and release.
The unit will follow its normal starting procedure. When the engine is running, the
left meter display will read AP W for the
weld module application update.
When the update has completed successfully, the Voltmeter/Ammeter display
reads: AL OK.
Failures are indicated on the meter display.
Correction of failed updates depends on
what type of failure occurred.
OM-281718 Page 37
A complete Parts List is available at www.MillerWelds.com
6-5. Summary File
1
1
Summary File
Each time a USB stick is inserted
in the USB receptacle when the
engine is running, a summary file
is saved to the USB stick as SummaryFile.txt.
“USB ACC” will display as the file
is written. File is complete when
display no longer shows “USB
ACC.”
The summary file provides diagnostic and weld information.
OM-281718 Page 38
A complete Parts List is available at www.MillerWelds.com
6-6. Fuel/Hour Gauge Descriptions
OM-281718 Page 39
A complete Parts List is available at www.MillerWelds.com
6-7. Auto Start/Stop Operation
1
3
2
Ref. 281316
Auto Start Controls
1 Engine Control Switch
After engine starts, place switch in the Auto
Start/Stop position.
2 Adjust Control/Select Button
Access service menu to adjust Stop Time
(see Section 6-3). Stop Time is the unit idle
time before an auto stop of the engine occurs.
Auto Start/Stop Operation
After starting the engine, the Engine Control switch defaults to Auto Start/Stop
mode. When in Auto Start/Stop, loads are
monitored for use. If no loads are present
and the engine is at idle, the Stop Time is
started. Upon timeout of the Stop Time, engine automatically stops. With the engine
stopped, air compressor output pressure
and truck (or system) battery voltage are
monitored for loads. If a load is detected,
the engine auto starts and normal operation
resumes.
When To Use Auto Start/Stop
Auto Start/Stop is recommended when air
and chassis power loads are used. For
welding, battery charging, and intermittent
auxiliary power loads, place Engine Control Switch in the Auto-Speed position.
Setting Stop Time
Press and hold Adjust Control/Select button for 5 seconds, then release to access
the Service Menu. Rotate the knob to scroll
through the menu items. Find STOP TIME
and press and release the select button.
OM-281718 Page 40
Scroll to select a STOP TIME between 2
and 30 minutes in increments of one
minute. Press and release the select button
to set the STOP TIME. Menu will timeout after 5 seconds of inactivity and the selection
will be saved.
Auto Start/Stop With Chassis Power
When the Engine Control switch is placed
in the Auto Start/Stop position and Chassis
Power (see Section 8) is selected, the engine automatically stops and restarts
based on chassis power load requirements. When the load drops below 10
amps, the engine automatically shuts off after a Stop Time timeout. After a minimum off
time of one minute, the control system
monitors the system battery voltage. When
the system battery voltage drops below
12.3 volts, as measured at the Main Control
board, the engine starting sequence is automatically initiated.
If the battery voltage drops below 12.3 volts
within the first two minutes of Auto Stop,
then the stop time will be overridden to 30
minutes. This will not change the time
saved in the stop time menu, but will stay at
30 minutes until the unit is manually power
cycled.
Auto Start/Stop With Air Compressor
3 Air Compressor Switch
When the Engine Control switch is placed
in the Auto Start/Stop position and the
Compressor switch is On, the engine automatically stops and restarts based on air
compressor load requirements. When the
compressor output pressure reaches Max
Pressure, the compressor reduces case
pressure while monitoring output pressure.
After 45 seconds of no use, the compressor clutch disengages and the engine idles.
Fifteen seconds after the engine idles, the
Stop Time starts. The engine auto stops
upon timeout of the Stop Time, and the
compressor output pressure is monitored.
A rapid drop in pressure or a pressure below Min Pressure auto starts the engine,
and normal compressor operation resumes. See Section 7 for setting compressor Min and Max Pressure.
Auto Start/Stop Without Chassis Power
And Without Air Compressor
When the Engine Control switch is placed
in the Auto Start/Stop position, both the air
compressor and chassis power are off, no
other loads are present, and the truck or
system battery voltage is above 12.3 volts,
the engine will automatically stop after a
Stop Time timeout. After a minimum off time
of one minute, the control system monitors
the system battery voltage. When the system battery voltage drops below 12.3 volts,
as measured at the Main Control board, the
engine starting sequence is automatically
initiated. The engine can be restarted by
turning on the air compressor, selecting
chassis power, or turning the Engine Control switch to Start.
!
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
A complete Parts List is available at www.MillerWelds.com
SECTION 7 − COMPRESSOR SYSTEM
7-1. Air Compressor Switch And Adjusting System Pressure
1
2
Ref. 281316
Weld output and generator power may
be reduced when the air compressor is
on.
Air Compressor Switch
1
Compressor Switch
Turn Compressor switch to On position to
turn compressor on. Turn switch to Off position to turn air compressor off.
Adjusting Air Pressure
2 Adjust Control/Select Button
When the air compressor switch is in On position, outlet air pressure is monitored. If
pressure is below MIN pressure setting,
compressor clutch engages and engine
speed increases to meet air demand. When
MAX pressure setting is reached, compressor case pressure reduces. If there is no air
demand for 45 seconds, the clutch disengages until outlet pressure is below MIN
setting. Access Service menu to set MIN
and MAX pressure settings (see Section
6-3). See Section 7-2 for air compressor
controls.
OM-281718 Page 41
A complete Parts List is available at www.MillerWelds.com
7-2. Air Compressor Controls
5
3
1
4
7
6
2
275810 / 277873
!
After the air compressor shuts off,
the blow down cycle begins and
takes several minutes. When gauge
reads zero, open cap slowly to release remaining pressure.
1 Air Compressor Case Pressure
Gauge
2 Pressure Sensor
Pressure sensor measures compressor
outlet pressure. A check valve in the compressor allows the outlet pressure to remain while the case pressure is reduced.
See Section 7-1 to set compressor pressure.
MAX pressure is factory set at 150 psi.
MIN pressure is factory set at 130 psi.
3 Over Pressure Switch (200 ± 10 psi)
Over pressure activates at 200 ± 10 psi
(1379 ± 69 kPa), disables compressor, and
displays AC OP (see Section 13-8). Power
to compressor is disabled until air compressor switch is turned off or case pressure is
reduced below 125 psi.
NOTICE − Frequent over pressure cycling
can cause clutch and belt damage.
4 Pressure Relief Valve
OM-281718 Page 42
The compressor is also equipped with a
mechanical safety valve (pressure relief
valve) that will open if pressure reaches
225 psi.
5
Temperature Sensor
Compressor shuts down due to overtemperature and AC TEMP displays (see
Section 13-8). The error condition automatically resets when temperature reduces.
Power to compressor is disabled until air
compressor switch is turned off.
Compressor Blow Down
6
Blow Down Valve
To prevent foaming or sudden release
of pressure, allow 10 minutes after
shutdown before opening the compressor fill cap or performing other
compressor maintenance.
To control the release of air mixed in the
compressor oil (while running), the compressor goes through a blow down cycle
when the compressor is turned off or the
engine is stopped. The blow down valve
slowly discharges the pressure in the compressor.
Compressor Idle Down And Standby
Mode
7 Compressor Outlet
When MAX pressure is reached, the blowdown valve is de-energized and the compressor begins reducing case pressure. If
no air is used, the compressor case pressure continues to drop. After 45 seconds,
the clutch disengages and the engine idles.
If there is a rapid pressure drop on the outlet
of the compressor, or if pressure is below
MIN pressure, the clutch and compressor
engage until MAX pressure is reached.
Compressor Auto Start/Stop
With engine control switch in Auto Start/
Stop position and Compressor switch On,
stop timer starts when compressor clutch is
disengaged. If stop timer is done, engine
turns off and compressor outlet pressure is
monitored. If outlet pressure becomes less
than the MIN pressure or drops rapidly, engine restarts and compressor clutch engages.
!
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
A complete Parts List is available at www.MillerWelds.com
7-3. Air Compressor Operation With Air Tools
10 Gallon
Minimum Air Tank
Connect a 10−gallon minimum air tank to
the air compressor outlet. The added air
volume will supplement the air output for
proper Auto Start/Stop function until the
Air Tool
compressor builds pressure.
For air usage greater than the compressor
output (30 CFM), the air tank supplements
air output for intermittent use. The more
the continuous CFM of the tool exceeds
the rating of the compressor, the larger the
tank that is needed for proper tool performance.
Average CFM
Continuous CFM
3/4 in. Impact Wrench (IR 2141)
10
40
3/4 in. Impact Wrench (Speedaire)
7
26
1/2 in. Impact Wrench (IR 231C)
4
22
Needle Scaler (IR 182LNA1)
3
13
4−1/2 in. Grinder (Dayton)
7
26
1/4 in. Die Grinder (IR G1H340RG4)
6
25
1/2 in. Drill (IR 7AQSTB)
4
17
Air Shears (IR 7802SA)
4
21
Sand Blaster
−−
6
Soda Blaster
−−
18
Button Punch/Deck Tool
−−
4
4
15
Decking Crimp Tool
OM-281718 Page 43
A complete Parts List is available at www.MillerWelds.com
SECTION 8 − CHASSIS POWER
8-1. Chassis Power And Auto Start/Stop Operation
Ref. 281316
1
!
2
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
Chassis Power Controls
1 Charge/Weld Switch
Place charge/weld switch in the charge position.
2 Process Switch
Place the process switch in the Chassis
Power position.
Chassis Power Operation
When Chassis Power is selected, weld/
charge output is connected directly to the
truck or system battery and up to 100 amps
of DC power is provided to the system. This
output is in addition to the output of the engine alternator, which is always supplying
power to the system battery when the engine is running. The engine alternator can
supply up to 60 amps depending on other
engine loads and generally keeps the sys-
OM-281718 Page 44
tem above 14 volts. If additional 12 volt DC
loads are added to the system, Chassis
Power adds power to maintain 14 volts DC
on the system.
In chassis power mode, weld and battery
charge outputs are not available. Chassis
Power can only be used with 12-volt DC
systems.
When To Use Chassis Power
Select Chassis Power when the truck or 12
volt system battery is expected to be under
constant loading of more than 10 amps of
DC power or intermittent loading of 100
amps or more.
Chassis Power is not needed for light continuous loads or infrequent moderate intermittent loading because the engine alternator will supply power to keep the truck or
system batteries charged.
Chassis Power Display
During Chassis Power operation the display alternates between “12V POWR” and
the actual voltage and amperage that the
weld/charge module is supplying.
Auto Start/Stop Operation
When the Engine Control Switch is placed
in the Auto Start/Stop position and Chassis
Power is selected, the engine will automatically stop and restart based on chassis
power load requirements. When the load
on the weld/charge module drops below 10
amps, the engine will automatically shut off
after the “STOP TIME” setting timeout (see
Section 6-3).
After a minimum off time of one minute, the
control system monitors the system battery voltage. When the system battery voltage drops below 12.3 volts, as measured
at the Main Control board, the engine starting sequence will automatically be initiated.
The air compressor control system also controls the auto start/stop functions. The engine may stop and start
depending on air load requirements.
See Section 6-7.
A complete Parts List is available at www.MillerWelds.com
SECTION 9 − BATTERY CHARGING
9-1. Battery Charging Guidelines
!
Stop engine.
!
!
Before charging battery, read the
Safety Precautions at the beginning of this manual.
!
Have only qualified persons do battery charging work.
!
Do not charge a defective battery, a
battery with loose terminals, or one
having evidence of damage such as
a cracked case or cover.
Keep battery charging cables away
from vehicle hood, door, and moving parts.
!
Do not use damaged battery charging cables.
!
Be sure charger output voltage
matches battery voltage.
!
Do not jump-start/crank assist a vehicle without a battery.
!
Never disconnect jump-start/crank
assist connections or cables when
charging or jumping/crank assisting. Clamps may be energized
when unit is in battery charge
mode.
!
Never place 12V battery on 24V only
setting.
9-2. Connecting Uninstalled Battery To Battery Charge Receptacle
Battery located outside of vehicle
3
1
5
+
2
6
4
−
7
282052−A
!
!
Stop engine. Place Air Compressor
switch in the Off position.
1
Battery Positive (+) Terminal
2
Battery Negative (−) Terminal
Before charging battery, check polarity of battery posts. Attach a 24 in.
(60 cm) AWG 6 insulated battery
cable to Negative (−) battery post.
Connect charger Positive (+) cable
to Positive (+) post of battery. Standing as far from battery as practical
and looking away from battery, connect charger Negative (−) cable to
the cable connected to the Negative
(−) battery post.
Obtain Battery Charge/Jumper Cable Kit
300422 or equivalent.
3
Red (Positive) Charging Cable
4
Black (Negative) Charging Cable
5
Battery Charge Plug
6
Battery Charge Receptacle
7
Insulated Battery Cable
(Customer-Supplied)
Connect a 24 in. (60 cm) or longer insulated
battery cable (AWG 6) to Negative (−) battery post. Connect red (Positive) battery
charging cable to battery Positive (+) post.
Connect black (Negative) battery charging
cable to insulated battery cable.
Connect Battery Charge plug to Battery
Charge receptacle.
NOTICE − Always connect cables to
battery first, then to Battery Charge receptacle.
OM-281718 Page 45
A complete Parts List is available at www.MillerWelds.com
9-3. Connecting Installed Battery To Battery Charge Receptacle
6
Battery located in vehicle
(Negative post grounded to chassis)
See
information below regarding vehicles
with battery Positive (+) grounded to chassis.
3
5
+
1
−
4
2
Connect black (Negative) char-
ging cable to chassis or engine
block (and away from battery).
282052−A
!
Stop engine. Place Air Compressor
switch in the Off position.
!
Before charging battery, check polarity of battery posts. If battery Negative (−) post is grounded to chassis
(most vehicles), connect charger
Positive (+) cable to Positive (+) ungrounded post of battery. Connect
charger Negative (−) cable to vehicle
engine block or heavy gauge metal
part of frame (and away from battery). If Positive (+) post is grounded
to chassis, connect charger Negative (−) cable to Negative (−) un-
OM-281718 Page 46
grounded post of battery. Connect
charger Positive (+) cable to vehicle
chassis or engine block (and away
from battery).
NOTICE − For equipment with sensitive
electronics, such as a vehicle with an onboard computer, disconnect battery from
vehicle or equipment before charging battery.
NOTICE − Never leave machine unattended when charging a battery.
1
Battery Positive (+) Terminal
2
Battery Negative (−) Terminal
Obtain Battery Charge/Jumper Cable Kit
300422 or equivalent.
3 Red (Positive) Charging Cable
4 Black (Negative) Charging Cable
5 Battery Charge Plug
6 Battery Charge Receptacle
7 Insulated Battery Cable
(Customer-Supplied)
Connect red (Positive) battery charging cable to battery Positive (+) post. Connect
black (Negative) battery charging cable to
engine block or heavy gauge metal part of
frame (and away from battery)
Connect Battery Charge plug to Battery
Charge receptacle.
A complete Parts List is available at www.MillerWelds.com
9-4. Setting Battery Charge Controls
!
Have only qualified
charge batteries.
!
Never place 12V battery on 24V
only setting.
1
Charge/Weld Switch
persons
Place switch in battery charge position.
2
Process Switch
Place switch in position matching voltage
of battery being charged. Weld power is
not available in battery charge mode.
Battery output is not energized until
battery is checked by unit.
Charging current automatically stops
when terminal current is below five
amps for five minutes.
Start engine and charge battery for 10
minutes. Check battery voltage. Continue
charging if necessary.
2
1
!
Stop engine when finished charging. Stand as far from battery as
practical and disconnect charging
cables from unit. Remove charging
cables from battery Negative (−)
cable first.
!
Always disconnect battery charge
plug before removing clamps.
Clamps may be energized when
unit is in battery charge mode.
Ref. 274580-C
9-5. Setting Battery Jump/Crank Assist Controls
!
Have only qualified persons
jump/crank assist batteries.
1
Charge/Weld Switch
Place switch in battery charge position.
2
Process Switch
Place switch in position matching
voltage of battery being crank assisted. Weld power is not available
in battery charge mode.
Battery output is not energized
until battery is checked by unit.
NOTICE − Do not attempt to crank
engine for intervals longer than 20
seconds. Output will shut down and
will reset when unit has cooled.
!
1
2
Stop engine when finished
charging. Stand as far from
battery as practical and disconnect charging cables
from unit. Remove charging
cables from battery Negative
(−) cable first.
Ref. 274580-C
OM-281718 Page 47
A complete Parts List is available at www.MillerWelds.com
9-6. Battery Charging Information On Display Screens
1
1
Display Screens
Display screens provide information
on charge mode, charging output,
and charging status. Explanations of
the display screen codes are
provided in the tables below.
Ref. 907760
A. Selected Charge Voltage And Output Voltage
12V
CHRG
Several seconds after the battery charger is turned on, the display screens indicate the selected charge
voltage, then switch to show output voltage and amperage at the battery charging receptacle.
25
14.8
B. Check Battery
BATT
CHEK
Code indicates the battery will not accept a charge, battery voltage does not match charging voltage, or
the system is improperly connected. Check battery and connections. Cycle Charge/Weld switch to restart
charging.
C. Jump Timeout
JUMP
WAIT
Code indicates the system was drawing too much current for too long of a time during an attempt to jump
start. Charge automatically restarts after cool down time.
BAD
The charger has determined that the battery is faulty and is unable to take a charge.
D. Battery Bad
BATT
Replace the battery.
E. Charge Complete
BATT
OM-281718 Page 48
DONE
The battery charge process has completed successfully.
A complete Parts List is available at www.MillerWelds.com
SECTION 10 − OPERATING AUXILIARY EQUIPMENT
10-1. Generator Power Receptacles And Supplementary Protectors
!
!
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.
10-2.
Unplug power cord before attempting
to service accessories or tools.
Generator power decreases as weld current or air compressor output increases.
Receptacles and circuit protection are customer supplied. Miller Auxiliary Power Remote Panel Kit 301512 can be connected to
machine.
Combined output of all receptacles limited to
6.5 kVA/kW rating of the generator.
GFCI Receptacle Information, Resetting, And Testing
1
Alternate
location for red
and green indicator LEDs.
2
5
4
3
Orientation of receptacle may be different in other applications.
!
!
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
RotGFCI3 2018-12
Testing GFCI Receptacles
Start engine and press the GFCI Test button. The GFCI Reset button should pop out.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine and access service menu (see
Section 6-3). Select RPM SET. Scroll to and
select 3600. Verify engine speed has increased to 3600 RPM. Press GFCI Reset
button. Access service menu again, select
RPM SET, and select AUTO. Verify engine
speed returns to 2400 RPM.
!
Test GFCI monthly.
!
If Red LED blinks, stop using GFCI
receptacle and have a Factory Authorized Service Agent replace it.
Reconnect equipment to GFCI receptacle.
If GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
!
Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
Have 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-281718 Page 49
A complete Parts List is available at www.MillerWelds.com
10-3. 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
3
1
4
Plug Wired for 120/240 V,
3-Wire Load
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
120V
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
5
120V
240V
6
2
3
4
240V
6
5
7
Current Available in Amperes
240 V
Each 120 V Duplex
Receptacle*
Receptacle
0
5
10
15
20
25
20
20
15
10
5
0
V x A = Watts
240 V AC
Tools Needed:
120 V AC
120 V AC
*One 240 V load or two 120 V loads.
plug1 11/03 − 120 813-D
OM-281718 Page 50
A complete Parts List is available at www.MillerWelds.com
SECTION 11 − WELDING OPERATION
11-1. 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)
250 ft
(70 m)
60 − 100%
Duty Cycle
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
* 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
11-2. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
The weld output terminals require
Tweco style connectors.
To connect base unit to weld output terminals, see Section 5-5.
1
2
282052
OM-281718 Page 51
A complete Parts List is available at www.MillerWelds.com
11-3. Weld Controls
3
2
1
4
7
6
5
281316
1
Charge/Weld Switch
Place switch in Weld position to energize
weld output terminals.
OM-281718 Page 52
2
3
4
Process Switch
Adjust Control/Select Button
Positive Weld Output Terminal
5
6
7
Negative Weld Output Terminal
Engine Control Switch
10-Pin Receptacle
A complete Parts List is available at www.MillerWelds.com
11-4. Arc Control Settings
Arc Control is not active when the Process switch is in the GTAW Lift-Arc TIG position.
Miller recommends Hobart filler metals.
Process Switch
Arc Control
SOFT
Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT
-12
(0)
Starting point for mild steel wire
STIFF
(1 to 25)
Starting point for aluminum wire (low inductance)
STIF
12
Voltage sensing feeder
SOFT
Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)
(0)
Starting point
STIFF
(1 to 25)
Stiffer, more rapidly responding arc for XX10 electrode
11-5. Stick Scratch Start
With Stick selected, start arc as
follows:
1
2
3
1
2
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted too high. If
electrode sticks to workpiece, use a
quick twist to free it.
Miller recommends Hobart filler
3
metals.
OM-281718 Page 53
A complete Parts List is available at www.MillerWelds.com
11-6. Lift-Arct TIG With Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc
1
Select Lift-Arc at Process switch.
Turn gas on.
2
1
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Auto-Stop
1
2
3
Arc End With Auto-Stop:
1
2
3
While welding.
Lift torch to start Auto-Stop.
Arc stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
WM Marketing
Notes
OM-281718 Page 54
A complete Parts List is available at www.MillerWelds.com
11-7. MIG Welding Connections And Settings
!
Stop engine.
This section provides general guide1
2
3
lines and may not suit all applications.
Work Clamp
Wire Feeder
MIG Gun
4
Gun Trigger Plug
5
Voltage Sensing Clamp
6
Gas Cylinder:
100 CO2/75/25 Argon-Based Gas for
Short Circuit Transfer
7
Gas Hose
Connect work cable to remote panel negative terminal. Connect cable from wire
feeder to remote panel positive terminal.
Be sure to use the correct size weld
cables (see Section 11-1).
Loosen MIG gun securing knob. Insert gun
end through opening in feeder and position
as close as possible to drive rolls without
touching. Tighten knob.
6
See wire feeder manual for wire threading
procedure.
7
Insert gun trigger plug (item 4) into matching receptacle and tighten threaded collar.
Connect gas hose from feeder to regulator
on cylinder.
Typical Control Settings For Short Circuit Transfer Using .035 (ER70S-3) Solid Wire And 100% CO2 Gas:
>
>
>
>
Quick connector
2
Set Process switch to GMAW.
Set weld voltage between 17 and 22
volts to obtain minimum spatter.
Set wire feed speed between 100
and 225 IPM.
Connection shown for GMAW.
Reverse electrode and work cables
for FCAW.
3
4
5
Work
1
Tools Needed:
3/4 in.
250 916-A / 802 766 / 250 290-C
OM-281718 Page 55
A complete Parts List is available at www.MillerWelds.com
11-8. Connecting Spool Gun
1
Spool Gun Plug
Insert plug into receptacle, and
tighten threaded collar.
2
3
Spoolmate 200 shown.
Weld Cable
Positive Weld Output Terminal
Connect weld cable to weld output
terminal.
4
5
Shielding Gas Hose
Regulator/Flowmeter (Not
Shown)
Route shielding gas hose up to
regulator/flowmeter. Connect gas
hose to fitting on regulator/flowmeter.
3
Work
2
4
1
Tools Needed:
3/4, 5/8 in.
805 243-A / 243 737-B
OM-281718 Page 56
A complete Parts List is available at www.MillerWelds.com
SECTION 12 − CAN-BUS CONNECTION
12-1. CAN-Bus Connection
1
3
2
CAN-Bus Connector
A CAN-bus connection is provided
to allow read-only data communication. The data is available through
the CAN-bus connector located in
the wiring harness underneath the
compressor compartment. Data is
transmitted when the unit is On. The
CAN port is transmit only.
5
2
3
4
4
5
1
Wedge Lock (Supplied)
(Deutsch W65-P012)
CAN Plug (Supplied) (Deutsch
DT06-6S-P012)
Terminal (Not Supplied)
(Deutsch 1062-16-0122)
Cabling (Customer Supplied)
Remove connector plug from receptacle located in harness under the
compressor compartment.
Disassemble plug and remove seals
as needed.
(Open)
Ground
+12 VDC
CAN High
Insert insulated wires (16 or 18
AWG) using Deutsch 1062-16-0122
terminals.
Cable Shield
CAN Low
Reassemble connector and reconnect to receptacle in harness.
238027-B
12-2. EnPak A30 J1939 Messages Diesel
Message
Notes
Acronym
ID (Hex)
PGN
(Decimal)
Start
Position
Length
SPN
(Decimal)
Tx
Rate
(ms)
Engine Speed
0 to 8031.875rpm 0.125rpm/bit offset
EEC1
0CF004E4
61444
4
2 bytes
190
20
Engine Coolant
Temperature
−40 to 210 degC, 1deg C/bit,
−40degC offset
ET1
18FEEEE4
65262
1
1 byte
110
1000
Battery Potential
(Voltage)
0 to 3212.75V, 0.05V/bit, 0 offset
VEP
18FEF7E4
65271
7
2 bytes
158
1000
Engine Oil Pressure
0 to 1000kPa, 4kPa/bit, 0 offset
Oil SW input is converted to fixed value:
off−>200kPa, on−>0kPa
EFL/P1
18FEEFE4
65263
4
1 byte
100
500
Active Diagnostics
See Figure 12-3.
DM1
18FECAE4
65226
Error State
See Figure 12-2.
proprietary
18FF78E4
65400
3
1 byte
516107
100
Engine Hours
Actual engine hours 0 to 65535 hours 1
hour/bit 0 offset
proprietary
1CFF79E4
65401
1
2 bytes
516110
1000
Engine Maintenance
Hours
Actual hours until engine oil change is required −32767 to 32767 hours 1 hour/bit 0
offset
proprietary
1CFF79E4
65401
3
2 bytes
516111
1000
Compressor Hours
Actual compressor clutch on hours 0 to
65535 hours 1 hour/bit 0 offset
proprietary
1CFF79E4
65401
5
2 bytes
516112
1000
Compressor Maintenance Hours
Actual hours until compressor oil change is
required −32767 to 32767 hours 1 hour/bit 0
offset
proprietary
1CFF79E4
65401
7
2 bytes
516113
1000
1000
OM-281718 Page 57
A complete Parts List is available at www.MillerWelds.com
Figure 12-1. J1939 Name For Address Claim
Field
Value
Industry Group
5
Vehicle System Instance
0
Vehicle System
0
Function
129
Function Instance
1
ECU Instance
1
MFG Code
402
Identity Number
1
Source Address
228
Notes
Industrial−Process Control−Stationary (Gen−Sets)
Generator Set Controller
Simma Software
Figure 12-2. Error State
Error
Value
Detection
NO ERROR
0
WELD MODULE OVER TEMP
5
Internal temperature of welder has exceeded the maximum limit.
WELD MODULE OUTPUT SHORTED
6
CV process has not cleared a short in 200 ms
WELD MODULE FAN TACH ERROR
7
The fan is running too slow or is damaged
WELD MODULE PRIMARY THERMISTOR ERROR
8
The primary circuit thermistor is reading too high or too low for a valid temperature.
WELD MODULE SECONDARY THERMISTOR ERROR
9
The secondary circuit thermistor is reading too high or too low for a valid
temperature
WELD MODULE POWER FAIL
10
Primary side power failed.
WELD MODULE BOOST ERROR
11
The primary boost has not successfully been established
WELD MODULE OVER VOLTAGE
12
Primary voltage is above 310 volts.
WELD MODULE UNDER VOLTAGE
13
The primary voltage is below 90 volts.
WELD MODULE COMMUNICATION ERROR
14
Weld module is not communicating with control board
WELD MODULE STUCK ELECTRODE
15
Stick welding electrode has become stuck in weld puddle and turned output
off.
Tungsten electrode has become stuck in weld puddle and turned output off.
WELD MODULE GUN CONNECT ERROR
16
A process that requires a welding gun to be attached is selected but the gun
is not attached
WELD MODULE GUN REMOVE ERROR
17
A process that does not require a welding gun to be attached is selected but
the gun is attached
WELD MODULE POWER UP ERROR
18
Power up timeout. Longer than 7 seconds to power up
WELD MODULE BOOT ERROR
19
Corrupt weld application
AIR COMPRESSOR OVER PRESSURE
20
Tank pressure over 190 psi. Reduce tank pressure to 125 psi to clear
AIR COMPRESSOR OVER TEMPERATURE
21
Air compressor oil temp over 120 C
AIR COMPRESSOR THERMISTOR OPEN
22
Air compressor thermistor reading below valid temperature
AIR COMPRESSOR THERMISTOR SHORTED
23
Air compressor thermistor reading above valid temperature
AIR COMPRESSOR TRANSDUCER HIGH
24
Air compressor pressure transducer reading above valid pressure
AIR COMPRESSOR TRANSDUCER LOW
25
Air compressor pressure transducer reading below valid pressure
ENGINE OIL LOW PRESSURE ERROR
26
Despite rpm, oil pressure switch is ON
ENGINE COOLANT OVER TEMPERATURE ERROR
27
Engine water temperature > 115C (239F)
ENGINE COOLANT SENSE SHORTED
28
Voltage of coolant temperature sensor is 4.9 V or above
ENGINE COOLANT SENSE GOUNDED
29
Voltage of coolant temperature sensor is 0.1 V or less
ENGINE BATTERY FAILURE
30
ECU recognition of battery voltage is above 18 V.
ENGINE SPEED OVERRUN
31
Engine speed >4140 min−1 (rpm)
ENGINE UNDER VOLTAGE
32
Voltage to sensor is below 4.00 V
ENGINE ACTUATOR CURRENT ERROR
33
Actuator current >3.0A or < 80mA
ENGINE SPEED SENSOR ABNORMAL
34
Engine speed = 0 min−1 (rpm) after Starter signal into ECU
OM-281718 Page 58
A complete Parts List is available at www.MillerWelds.com
Error
Value
Detection
ENGINE STARTER ERROR
35
Starter running time is above 12sec
ENGINE ALTERNATOR ABNORMAL
36
Alternator L terminal has voltage while 0 rpm (After Key On)
ENGINE BATTERY CHARGING ERROR
37
Alternator L terminal is 0 V while engine is running
ENGINE CAN COMM ERROR
38
CAN Bus OFF
TRUCK INTERLOCK SIGNAL NOT PRESENT
41
Missing 12V to interlock
Figure 12-3. DM1 Definitions
SPN Name
SAE J1939
Table C1
J1939−73
DTC
Detection
DTC Set Parameter
Time to action or
number of error
detection
ECU
Action
Recovery
From
Error
SPN
FMI
Oil pressure error
100
1
Engine Oil
Pressure
Oil pressure switch
Despite rpm, oil pres- 1.0 sec or more
sure switch is ON
Engine
Stop
Key switch
turn OFF
Engine overheat
110
0
Engine
Coolant Temperature
Overheat of engine wa- Engine water temper- 1.0 sec or more
ter temperature
ature w 115C (239F)
Engine
Stop
Key switch
turn OFF
Water temperature
sensor: High
110
3
Engine
Coolant Temperature
Open circuit of sensor / Voltage of coolant
harness, + B short cir- temperature sensor
cuit
is 4.9 V or above
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Water temperature
sensor: Low
110
4
Engine
Coolant Temperature
Ground short circuit of
sensor / harness
Voltage of coolant
temperature sensor
is 0.1 V or less
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Battery voltage:
High
158
3
Battery Poten- Open circuit, short cir- ECU recognition of
tial (Voltage)
cuit, or damage of har- battery voltage is
Switched
ness. Failure of battery above 18 V.
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Engine overrun
190
0
Engine Speed
Engine speed exceeds Engine speed >4140
threshold speed
rpm
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Sensor supply voltage 1: Low
3509
4
Sensor supply
voltage 1
Sensor supply voltage
1
Voltage to sensor is
below 4.00 V
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Actuator Abnormal
5E+05
2
proprietary
Open circuit, short circuit, or damage of harness.
Actuator current
>3.0A or < 80mA
1.0 sec or more
Engine
Stop
Key switch
turn OFF
Engine Speed Sen- 5E+05
sor Abnormal
2
proprietary
Open circuit, short circuit, or damage of harness.
Engine speed = 0
min−1 (rpm) after
Starter signal into
ECU
30.0 sec or more
Engine
Stop
Key switch
turn OFF
Starter error
5E+05
2
proprietary
Starter running time
exceed threshold time
Starter running time
is above 12sec
12.0 sec or more
Engine
Stop
Key switch
turn OFF
Charging failure
5E+05
2
proprietary
Open circuit, short circuit, or damage of harness
Alternator L terminal 1.0 sec or more
is 0 V while engine is
running
Engine
Stop
Key switch
turn OFF
CAN Communication Abnormal
5E+05
2
proprietary
CAN Bus
CAN Bus OFF
−
−
−
Emergency Stop
switch
Emergency Stop
0.1 sec or more
CAN Signal into ECU
Emergency Stop
0.2 sec or more
Key switch
turn OFF
Engine
Stop
Key switch
turn OFF
Figure 12-4. CAN Specification
Communication Protocol
SAE J1939
Format Type
Extended Format (ID:29bit)
Baud Rate
250kbps
Sample Point
80%
Number of Sample
1
SJW
2Tq
Terminal Resistor
120 ohms
OM-281718 Page 59
A complete Parts List is available at www.MillerWelds.com
SECTION 13 − MAINTENANCE AND TROUBLESHOOTING
13-1. Maintenance Label
281700-A
OM-281718 Page 60
A complete Parts List is available at www.MillerWelds.com
13-2. Routine Maintenance
Recycle
engine
fluids.
!
Stop engine before maintaining.
!
Always put Engine Control Switch in the Off position
before working on unit to prevent automatic starting.
See Maintenance Label for important start-up, service, and
storage information. Service more often if used in severe
conditions.
Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by a Factory Authorized Service Agent.
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.
Replace compressor oil and filter after the first 50 hours of operation.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Replace
Reference
Every
8
Hours
Sections
5-10, 6-1,
7-1
Compressor And
Engine Oil Level
Fluid Spills
Meter For Next Oil
Change Interval
Every
200
Hours
Section
13-4, Engine Manual
5/16 in.
(8 mm)
Fuel Connections
Engine Oil
Weld Terminals
Engine Oil Filter
Engine Fan
Belt Tension
Engine Air Cleaner
Unreadable Labels
Every
250
Hours
Engine
Manual,
Section
13-5
Every
400
Hours
Fuel Filters
Compressor Air
Cleaner Element
Every
500
Hours
Or
Yearly
Section
13-3, Engine Manual
Compressor Oil
Compressor Oil Filter
Every
1000
Hours
Air & Control Lines For Wear & Aging
Weld Cables
Compressor Belt
Condition/Tension
Engine
Manual
OR
Air/Oil Separator
Inside Unit
Flush Radiator
Radiator Hoses
Every
2000
Hours
Slip Rings*
Brushes*
Air Cleaner Hoses
Engine
Manual,
Section
13-6
Fuel Hoses
Coolant & Hoses
Engine Fan Belt
Compressor Fan
Belt
NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.
OM-281718 Page 61
A complete Parts List is available at www.MillerWelds.com
13-3. Changing Compressor Oil, Oil Filter, Air Cleaner, And Air/Oil Separator
!
Stop engine.
!
Always put Engine Control Switch in the
Off position before working on unit to
prevent automatic starting.
!
Do not open oil fill cap until unit has been
off for 10 minutes and the air compressor gauge reads zero. Do not open while
running.
!
Do not run air compressor without air
cleaner or with dirty element. Compressor damage caused by using a damaged
element is not covered by the warranty.
1
Compressor Air Cleaner Cover
2
Air Cleaner Element
Tools Needed:
Wipe off cover. Remove cover and element.
Wipe dust from cover and housing with damp
cloth. Inspect element and install new element
if necessary. Reinstall cover.
!
Do not clean element with compressed
air.
3
Air/Oil Separator
To replace air/oil separator:
Turn filter counterclockwise. Remove filter.
Apply thin coat of oil to gasket on new filter. Install filter and turn clockwise 1/2 to 3/4 turn after
gasket contact is made.
2
4
Air Compressor Oil Filter
5
Air Compressor Oil Drain Plug
6
Oil Fill Pipe Cap
To change compressor oil and filter:
Drain compressor oil while compressor is still
warm.
Remove oil drain plug to drain oil.
3
Remove filter by turning filter counterclockwise.
Apply thin coat of oil to gasket on new filter. Install new filter and turn clockwise 1/2 to 3/4 turn
after gasket contact is made.
1
Reinstall oil drain plug and torque to 12 ft lb.
Add recommended oil until oil level is half way up
oil fill pipe (see maintenance label for oil specifications). Reinstall oil fill cap. Hand−tighten cap
to prevent pressure release or oil leak.
Bottom of oil sight glass is minimum oil level.
Top of oil sight glass is full.
Start engine, run air compressor, and check for
oil leaks.
!
Stop engine.
Check oil level and top off to fill line if necessary.
High/Max
Low/Min
6
4
Bottom
of oil sight
glass is minimum oil
level. Top of oil sight
glass is full.
5
907759
OM-281718 Page 62
A complete Parts List is available at www.MillerWelds.com
13-4. Replacing Engine Air Cleaner
!
Stop engine.
!
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
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 Cleaner
2
Air Cleaner Clamp
3
Housing
4
Safety Element (Optional)
5
Primary Element
6
Cover
7
Dust Ejector
Remove air cleaner clamp. Pull air cleaner out slightly and remove bottom cover.
Remove air cleaner element and replace
with new element. Reinstall air cleaner
cover and clamp.
Replace air cleaner element every 200
hours or less if used in severe conditions.
1
2
3
Optional
4
5
7
6
907759
OM-281718 Page 63
A complete Parts List is available at www.MillerWelds.com
13-5. Changing Engine Oil, Oil Filter, And Fuel Filter
Tools Needed:
Oil Fill
3
2
Oil Check
Full
1
Ref. 907760
!
Stop engine and let cool.
!
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
To change engine oil and oil filter:
1
Oil Drain Valve
2
Oil Filter
OM-281718 Page 64
Remove plastic plug on side of base and
route 1/2 in. oil drain hose through hole in
base. Change engine oil and filter according to engine owner’s 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 5-9).
To change fuel filter:
3 Fuel Filter
Spin off filter, using filter wrench if needed.
Install new fuel filter and hand tighten.
Start engine to prime fuel system and
check for leaks. Access service menu to
reset oil change countdown. See Section
6-3.
!
Stop engine, tighten connections as
necessary, and wipe up fuel.
A complete Parts List is available at www.MillerWelds.com
13-6. Changing Engine Coolant
Tools Needed:
3/8 in.
1
3
2
907759
!
!
Stop engine and let cool.
Always put Engine Control Switch
in the Off position before working
on unit to prevent automatic starting.
1 Radiator Cap
2 Engine Coolant Drain Valve
3 Radiator Housing
To drain engine coolant:
With engine off and cold, remove radiator
cap slowly. Install hose on engine coolant
drain valve and route hose into a container.
Open coolant drain valve on side of engine
block and allow coolant to drain. Close
drain valve on side of engine block.
Coolant fill procedure:
Slowly fill cooling system with 50% water/
antifreeze solution until full.
Install radiator cap and remove two fasten-
ers from radiator housing. Tilt up radiator to
purge air from cooling system.
Lower radiator and add coolant.
Repeat the preceding steps until no more
coolant can be added. Fill overflow reservoir to FULL indicator. Reinstall fasteners.
Run engine at idle with no load for 15 minutes. Let cool and top off radiator.
NOTICE − Air in engine cooling system can
damage engine.
OM-281718 Page 65
A complete Parts List is available at www.MillerWelds.com
13-7. Overload Protection
!
Stop engine.
!
Always put Engine Control
Switch in the Off position before working on unit to prevent automatic starting.
When a circuit breaker, supplementary protector or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
1
Supplementary Protector CB1
CB1 is located inside the air compressor access door next to the AC
terminal strip.
2
Fuse/Relay Module Label
Engine and control fuses are located in the fuse/relay module located
in the compressor compartment.
Fuses protect engine and control
components.
1
2
OM-281718 Page 66
A complete Parts List is available at www.MillerWelds.com
13-8. Voltmeter/Ammeter Error Displays
WELD
TEMP
Display Example
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions.
When an error is displayed, normally weld output has stopped but generator power output may be okay.
To reset error displays, stop unit and then restart.
Error Display
Error Name
Description
Remedy
S/W ERR
Software Version Mismatch Or Invalid
Different software versions among PC
boards.
Reload software.
ID ERR
Invalid Product Id
Invalid ID resistor in harness.
Have factory authorized service agent
check ID resistor in harness.
COMM ERR
Can Communications Error
CAN communication timeout between UI
and control board.
Have factory authorized service agent
check CAN signals from UI.
WELD TEMP
Weld Module Over Temp
Internal temperature of welder has exceeded the maximum limit.
Wait for unit to cool down.
WELD SHRT
Weld Module Output Shorted
CV process has not cleared a short in 200
ms.
Manually clear short between electrode
and work.
WELD FAN
Weld Module Fan Tach Error
The fan is running too slow or is damaged.
Clear obstruction from fan. Reconnect
the fan.
WELD PRI
Weld Module Primary Thermistor
Error
The primary circuit thermistor is reading too Have factory authorized service agent
high or too low for a valid temperature.
check thermistor connection.
WELD SEC
Weld Module Secondary Thermistor The secondary circuit thermistor is reading
Error
too high or too low for a valid temperature.
Have factory authorized service agent
check thermistor connection.
WELD PWRF
Weld Module Power Fail
Primary side power failed.
Cycle power to clear error.
WELD BST
Weld Module Boost Error
The primary boost has not successfully
been established.
Cycle power to clear error.
WELD OV
Weld Module Over Voltage
Primary voltage is above 310 volts.
Cycle power to clear error.
WELD UV
Weld Module Under Voltage
Primary voltage is below 90 volts.
Cycle power to clear error.
WELD COMM
Weld Module Communication Error
Weld module is not communicating with
control board or no power to weld module
(CB1 tripped).
Check CB1. Check for generator power.
Have factory authorized service agent
check power to PC1, and connections
between PC1 and PC3.
WELD STCK
Weld Module Stuck Electrode
Stick or Tungsten electrode has become
stuck in weld puddle and turned output off.
Remove Stick or Tungsten electrode
from workpiece, and output will turn
back on after about one second.
GUN CON
Weld Module Gun Connect Error
A process that requires a welding gun to be Connect gun or change process.
attached is selected, but the gun is not attached.
GUN REM
Weld Module Gun Remove Error
A process that does not require a welding
gun to be attached is selected, but the gun
is attached.
Disconnect gun or change process.
WELD PRUP
Weld Module Power Up Error
Power up timeout:. Longer than 7 seconds
to power up.
Cycle power to clear error.
WELD BOOT
Weld Module Error Launching
Application
Weld module is communicating but the application is corrupt.
Perform software update.
AC OP
Air Compressor Over Pressure
Tank pressure over 190 psi.
Reduce tank pressure to 125 psi to
clear error.
AC TEMP
Air Compressor Over Temperature
Air compressor oil temp over 248°F
(120°C).
Error clears when oil temp is less than
248°F (120°C).
ACTM OPEN
Air Compressor Thermistor Open
Air compressor thermistor reading below
valid temperature.
Have factory authorized service agent
check thermistor connection.
ACTM SHRT
Air Compressor Thermistor Shorted Air compressor thermistor reading above
valid temperature.
Have factory authorized service agent
check thermistor connection.
ACTD HIGH
Air Compressor Transducer High
Voltage
Air compressor pressure transducer reading Have factory authorized service agent
above valid pressure.
check pressure transducer.
ACTD LOW
Air Compressor Transducer Low
Voltage
Air compressor pressure transducer reading Have factory authorized service agent
below valid pressure.
check pressure transducer connection.
OM-281718 Page 67
A complete Parts List is available at www.MillerWelds.com
Error Display
Error Name
Description
Remedy
OIL PRES
Engine Oil Low Pressure Error
Despite RPM, oil pressure switch is ON.
Turn key switch OFF.
H2O TEMP
Engine Coolant Over Temperature
Error
Engine water temperature greater than or
equal to 239°F (115°C).
Turn key switch OFF.
H2O SHRT
Engine Coolant Sense Shorted
Voltage of coolant temperature sensor is 4.9 Turn key switch OFF.
volts or above
H2O GND
Engine Coolant Sense Grounded
Voltage of coolant temperature sensor is 0.1 Turn key switch OFF.
volts or less.
ENG BATT
Engine Battery Failure
ECU recognition of battery voltage is
above 18 volts.
Turn key switch OFF.
ENG SPD
Engine Speed Overrun
Engine speed is greater than 4140 RPM.
Turn key switch OFF.
ENG VOLT
Engine Under Voltage
Voltage to sensor is below 4 volts.
Turn key switch OFF.
ENG ACT
Engine Actuator Current Error
Actuator current greater than 3.0 A or less
than 80 mA.
Turn key switch OFF.
SPD SENS
Engine Speed Sensor Abnormal
Engine speed is 0 RPM after Starter signal
into ECU.
Turn key switch OFF.
ENG STRT
Engine Starter Error
Starter running time is above 12 seconds.
Turn key switch OFF.
ENG ALT
Engine Alternator Abnormal
Alternator L terminal has voltage while 0
RPM (After Key On).
Turn key switch OFF.
ENG CHRG
Engine Battery Charging Error
Alternator L terminal is 0 volts while engine
is running.
Turn key switch OFF.
ENG COMM
Engine Can Comm Error
CAN Bus OFF.
Turn key switch OFF.
INTRLOCK
Truck Interlock Signal Not Present
EnPak Models only.
Apply 12V signal to interlock input.
13-9. Troubleshooting
A. Compressor Troubleshooting
Trouble
Remedy
Air compressor does not operate; no air Place Air Compressor switch in an On position. If compressor is turned off, wait for air pressure to bleed
pressure on gauge; no clutch off before turning compressor on again.
engagement.
Pressure downstream of compressor outlet above MIN pressure setting keeps compressor from engaging. Compressor will engage when outlet pressure reduces below MIN pressure. See Section 7-1 for
pressure setting procedure.
Check for over pressure. Check pressure settings and reduce if necessary (see Section 7-1). Turn Air
Compressor switch off to reset.
Check for over temperature. Allow unit to cool. Recirculation or open covers may cause overheating. Be
sure all covers, panels, and doors are in place. Operate in area with proper airflow. Automatic shutdown
stops compressor if compressor temperature is too high.
Check compressor belt and tension. Be sure correct belt is used and is properly installed. Replace belt
if damaged or worn.
Have Factory Authorized Service Agent check air compressor control circuit and clutch.
Air compressor stops producing air, or Compressor idle down causes compressor to turn off when set pressure is reached. See Section 7-2.
air compressor cycles on and off.
During air use, compressor pressure will continue to decrease if using more than 30 CFM. Decrease load,
or allow compressor to build pressure between loads. Compressor will automatically produce air when
a load is applied, unless it is a light load such as an air leak. For light loads, pressure will decrease to MIN
pressure and then increase to MAX pressure.
Check for air leaks downstream of compressor outlet. Air leaks cause more frequent compressor cycling.
Repair all air leaks.
Check for over pressure. Check pressure settings and reduce if necessary (see Section 7-1). Turn Air
Compressor switch off to reset.
Check compressor oil level (see Section 5-10). Automatic shutdown stops compressor if compressor
temperature is too high.
OM-281718 Page 68
A complete Parts List is available at www.MillerWelds.com
Trouble
Remedy
Air compressor stops producing air, or Check for over temperature. Allow unit to cool. Recirculation or open covers may cause overheating. Be
air compressor cycles on and off (contin- sure all covers, panels, and doors are in place. Operate in area with proper airflow. Automatic shutdown
ued).
stops compressor if compressor temperature is too high.
Have Factory Authorized Service Agent check and clean compressor cooler core. Automatic shutdown
stops compressor if compressor temperature is too high.
Verify adequate air flow to compressor. Check for blocked air intake.
Have Factory Authorized Service Agent check operation of over pressure switch S2.
Compressor operates, but air pressure Check for leaks in air lines and hoses.
is low.
Adjust compressor air pressure (see Section 7-2).
Reduce air demand/close air outlet valve.
Run compressor to increase temperature above freezing.
Check for frozen lines or hoses downstream from compressor outlet.
Blowdown valve is frozen. Run compressor to build heat and blowdown valve will return to normal operation.
Check air compressor air cleaner (see Section 13-3).
Check compressor oil level (see Section 5-10).
Check air/oil separator, and replace if plugged (see Section 13-3).
Check compressor belt and tension. Be sure correct belt is used and is properly installed. Replace belt
if damaged or worn.
Have Factory Authorized Service Agent check solenoid blow down valve, and for leaks in control lines.
Also check air compressor for rated output.
High air pressure.
Check air compressor gauge. Adjust compressor air pressure (see Section 7-2).
Check for frozen control lines.
Oil in air from compressor.
Check compressor oil level (see Section 5-10). If oil level is too high, system becomes saturated with oil.
Open line (nothing connected to compressor outlet) will result in oil in air. Do not operate with open air
line.
Change compressor air/oil separator if close to replacement hours (see Section 13-3).
Wrong or mixed oil results in foaming which can cause oil in air. If mixed oil is suspected, replace oil, oil
filter, and air/oil separator.
Have Factory Authorized Service Agent check for plugged oil scavenge line.
Engine does not idle with compressor Remove auxiliary power or other loads. Multiple loads keep engine at high speed.
on.
Wait 45 seconds after air output stops for engine to idle. Verify case pressure reduces during this time.
Check for air leaks downstream of compressor. Any air leak will cause output pressure to reduce and the
compressor to engage.
When pressure reduces in case, verify clutch disengages 45 seconds after air output stops. If it does not,
check for air leaks.
Air compressor overheats. Display Check that all covers, panels, and doors are in place during operation.
reads “AC TEMP.”
Check compressor oil level (see Section 5-9). Low oil level causes increased compressor temperature.
Automatic shutdown stops compressor if compressor temperature is too high.
Recirculation or open covers may cause overheating. Be sure all covers, panels, and doors are in place.
Operate in area with proper airflow. Automatic shutdown stops compressor if compressor temperature
is too high.
Check/clean oil cooler.
Verify adequate air flow to compressor. Check for blocked air intake.
Adjust compressor air pressure (see Section 7-2).
Replace compressor oil filter (see Section 13-3).
Wrong oil or mixed oil. Drain oil and replace with factory oil and filter.
Have Factory Authorized Service Agent check temperature sensor.
OM-281718 Page 69
A complete Parts List is available at www.MillerWelds.com
Trouble
Oil in compressor air cleaner.
Remedy
Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.
Water in compressor oil. Oil appears Operate air compressor continuously under pressure to allow the compressor to reach operating tempermilky.
ature. Water in oil is often caused by intermittent use in which compressor does not reach temperature.
If oil still appears milky, change oil, oil filter, and air/oil separator.
Water in air from compressor.
Some water in air from compressor is normal. Install air line water separator if necessary.
Compressor case retains pressure after Have Factory Authorized Service Agent check compressor blow down valve.
shutdown.
B. Battery Charge/Jump-start/Crank Assist Troubleshooting
Trouble
Remedy
No battery charge/jump start/crank as- Be sure battery is connected.
sist output.
Check polarity.
Be sure Process switch is in 12V or 24V position according to the voltage of the battery being charged.
Be sure Charge/Weld switch is in charge position.
Check battery voltage. Charging may be finished.
Have Factory Authorized Service Agent check battery charge circuitry.
Charging current turns on and off while Clean and tighten battery connections, if necessary. Clean battery terminals and posts with baking soda
charging battery.
solution and rinse with clear water.
Check condition of battery.
C. Generator Power Troubleshooting
Trouble
No or low generator power output at
AC receptacles.
Remedy
Reset supplementary protector(s) (see Section 13-7).
Access service menu to view engine speed (see Section 6-3). Verify engine speed increases to 3600 rpm
with auxiliary power load.
Have Factory Authorized Service Agent check brushes and slip rings and PC2.
Be sure all equipment is disconnected from receptacles when starting unit.
Low power output at AC receptacles.
Access service menu to view engine speed (see Section 6-3). Verify engine speed increases to 3600 rpm
with auxiliary power load.
Verify there is no weld load.
High power output at AC receptacles.
Access service menu to view engine speed (see Section 6-3). Verify engine speed increases to 3600 rpm
with auxiliary power load.
Erratic power output at AC
receptacles.
Check fuel level.
Access service menu to view engine speed (see Section 6-3). Verify engine speed increases to 3600 rpm
with auxiliary power load.
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes and slip rings and PC2.
D. Welding Troubleshooting
Trouble
No weld output or generator power output at AC receptacles.
Remedy
Be sure all equipment is disconnected from receptacles when starting unit.
Check and reset circuit breaker CB1.
Have Factory Authorized Service Agent check brushes and slip rings and PC2.
No weld output; generator power output okay at AC receptacles.
Check weld connections.
Be sure Charge/Weld switch is in weld position.
Have Factory Authorized Service Agent check PC1 and weld/battery charge inverter.
No weld output during generator power Reduce generator load.
load.
OM-281718 Page 70
A complete Parts List is available at www.MillerWelds.com
Trouble
Low weld output.
Remedy
Check Weld Output control setting.
Be sure Charge/Weld switch is in weld position.
Check weld cable size and length.
Access service menu to view engine speed (see Section 6-3).
Service engine air cleaner (see Section 13-4). Service engine fuel filter (see Section 13-5).
Have Factory Authorized Service Agent check PC1 and weld/battery charge inverter.
High weld output.
Check Weld Output control setting.
Erratic weld output.
Check Weld Output control setting.
Tighten and clean connections to electrode and workpiece.
Use dry, properly stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welder/generator.
Access service menu to view engine speed (see Section 6-3).
Service engine air cleaner (see Section 13-4). Service engine fuel filter (see Section 13-5).
E. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
“INTRLOCK” displayed. Connect 12V signal to interlock input.
Check engine fuses and replace if open (see Section 13-7).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG8 (ignition switch).
Have Factory Authorized Service Agent check Engine Control switch S1.
Engine will not start.
Check fuel level.
Check battery voltage.
Check battery connections and tighten if necessary.
Check oil level (see Section 5-9).
Have Factory Authorized Service Agent check low oil pressure shutdown switch.
Engine starts but stops when Engine
Control switch returns to Auto Start/
Stop position.
Check oil level.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.
Check low oil pressure shutdown switch.
Engine stopped during normal
operation.
Check fuel level.
Replace fuel filter(s) (see Section 13-5).
Check oil level (see Section 5-9).
Check low oil pressure shutdown switch.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Have Factory Authorized Service Agent check engine.
Battery discharges between uses.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Check alternator and connections according to engine manual.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Engine idles but does not come up to
weld speed.
Have Factory Authorized Service Agent check current transformer CT1.
Unstable or sluggish engine speeds.
Check oil level. Oil level should not exceed Full mark on dipstick.
Tune-up engine according to engine manual.
Engine does not return to idle speed.
Remove weld and generator power loads.
Have Factory Authorized Service Agent check current transformer CT1 and Engine Control switch S1.
OM-281718 Page 71
A complete Parts List is available at www.MillerWelds.com
SECTION 14 − PARTS LIST
14-1. Recommended Spare Parts
Dia.
Mkgs.
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
. . . . . . . . . . . F2 . . . . .
. . . . . . . . . . F3-F4 . . .
. . . . . . . . . . F5-F6 . . .
. . . . . . . . . . CR1 . . . .
. . . . . . . . CR2-CR6 . .
....................
OM-281718 Page 72
Part
No.
276418
493509
274630
275644
232207
275648
262573
276620
284101
187443
187441
259934
283082
187820
281760
281759
281758
281756
281755
222093
Description
Quantity
. . USB Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Belt, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Filter/Separator, Compressor (Includes) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, Oil Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Separator, Oil/Air Rotary Screw Compressor . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, Inlet Air Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil, Air Compressor Rotary Screw(Synthetic)(Quart) . . . . . . . . . . . . . . . .
. . Tune-Up & Filter Kit, Kubota (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Engine Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuel Primary Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Engine Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuse, Mini Blade Atm 20. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuse, Mini Blade Atm 10. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuse, Mini Blade Atm 5. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Relay, Encl 12VDC Spst 35A Skt Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Relay, Encl 12VDC Spst 20A Skt Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rcpt, Str Dx Grd GFCI w/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
5
2
A complete Parts List is available at www.MillerWelds.com
Notes
OM-281718 Page 73
SECTION 15 − DIAGRAMS
Figure 13-1. Circuit Diagram For Welder/Generator, Page 1 Of 2
OM-281718 Page 74
281320-A
OM-281718 Page 75
281320-A
Figure 13-2. Circuit Diagram For Welder/Generator, Page 2 Of 2
OM-281718 Page 76
281706-A
Figure 13-3. Air Compressor Schematic
OM-281718 Page 77
SECTION 16 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown.
16-1. Selecting Equipment
1
2
1
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
!
2
Do not use 2-prong plug unless equipment is double
insulated.
3
OR
gen_pwr 2018−06 − ST-800 577
16-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
OM-281718 Page 78
3
Metal Vehicle Frame
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
!
Bed liners, shipping skids, and
some running gear insulate the
welder/generator from the vehicle
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
16-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
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
16-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive
load
and
requires
approximately six times more power
while starting the motor than when
running (see Section 16-8).
VOLTS 115
AMPS 4.5
Hz
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-281718 Page 79
16-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
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
16-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
Farm Duty Motors Std. (e.g. Conveyors, Feed
Augers, Air Compressors)
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-281718 Page 80
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
16-7. 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-281718 Page 81
16-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welder/generator amperage output
must be at least twice the motor’s
running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
16-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-281718 Page 82
16-10. 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 16-4).
OM-281718 Page 83
16-11. 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-281718 Page 84
6 (16)
ENPAK ) EQUIPMENT
LIMITED WARRANTY
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
This limited warranty supersedes all previous EnPak warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the express terms and
conditions set forth below, Miller Electric Mfg. LLC,
Appleton, Wisconsin, warrants to the original retail
purchaser of new EnPak equipment (sold after the
effective date of this Limited Warranty) that such
equipment is free from defects in materials and
workmanship when shipped by Miller.
Visit our website at
www.MillerWelds.com/EnPak
to locate an EnPak supplier.
For warranty claims received by Miller within the applicable
warranty periods described below, Miller will repair or
replace any warranted equipment, parts or components
that fail due to defects in material or workmanship or refund
the purchase price for the equipment. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed. Notifications
submitted as online warranty claims must provide detailed
descriptions of the fault and troubleshooting steps taken to
diagnose failed parts. Warranty claims that lack the required
information as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.
Miller shall honor warranty claims on warranted equipment
in the event of a defect within the warranty coverage
periods listed below. Warranty time periods start on the
delivery date of the equipment to the end−user purchaser,
or 12 months after the equipment is shipped to a North
American or international distributor, whichever occurs
first.
1.
3 Years — Parts and Labor Unless Otherwise
Specified
* Engine Driven Generators (NOTE: engines are
warranted separately by the engine manufacturer.)
* Field options (NOTE: field options are covered for
the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
2.
90 Days — Parts
* Remote Controls
* Accessories (Kits)
* Replacement Parts (No labor)
* Canvas Covers
This Limited Warranty shall not apply to:
1.
Consumable components, such as contactors, relays
or parts that fail due to normal wear and use.
2.
Items furnished by Miller, but manufactured by others,
such as engines and trade accessories (these items
are covered by the manufacturer’s warranty, if any).
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards; or equipment which has not been
used and maintained in accordance with Miller’s
specifications; or equipment which has been operated
outside of Miller’s specifications for the equipment.
Miller products are intended for purchase and use by
commercial/industrial users and persons trained and
experienced in the use and maintenance of industrial
equipment.
Defects caused by accident, unauthorized repair, or
improper testing.
3.
4.
In the event of a warranty claim covered by this Limited
Warranty, the exclusive remedies shall be, at Miller’s sole
discretion: (i) repair; or (ii) replacement; (iii) where
authorized in writing by Miller in appropriate cases, the
reasonable cost of repair or replacement at an authorized
EnPak service facility; or (iv) payment of (or credit for) the
purchase price (less reasonable depreciation based upon
actual use) upon return of the equipment at the warranty
claimant’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Appleton, Wisconsin; (USA),
or F.O.B. an EnPak authorized service facility designated
in writing by Miller. No compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE GREATEST EXTENT PERMITTED BY
APPLICABLE LAW, THE REMEDIES PROVIDED
HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES
APPLICABLE TO THE ENPAK EQUIPMENT. IN NO
EVENT SHALL MILLER BECOME LIABLE FOR DIRECT,
INDIRECT, SPECIAL, PUNITIVE, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT OR LOST BUSINESS OPPORTUNITY),
WHETHER BASED IN CONTRACT, TORT OR ANY
OTHER LEGAL THEORY. IN NO EVENT SHALL MILLER
BECOME OBLIGATED TO PAY MORE ON ANY
WARRANTY CLAIM THAN THE PURCHASE PRICE
ACTUALLY PAID BY THE ORIGINAL RETAIL
PURCHASER.
THIS LIMITED WARRANTY IS MADE IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY AND/OR FITNESS FOR A
PARTICULAR PURPOSE, OR ANY OTHER WARRANTY
OR GUARANTEE ARISING BY OPERATION OF LAW.
ANY WARRANTY NOT EXPRESSLY PROVIDED
HEREIN, IMPLIED WARRANTY, GUARANTY AND ANY
OR
REPRESENTATION
REGARDING
THE
PERFORMANCE OF THE EQUIPMENT, AND ANY
REMEDY FOR BREACH OF CONTRACT, IN TORT, OR
ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE, OR
COURSE OF DEALING ARE EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the United States of America do not allow
limitations of how long an implied warranty lasts, or the
exclusion of incidental, indirect, special or consequential
damages, such the above limitations and exclusions may
not apply to you. This warranty provides specific legal
rights. Other rights may be available to you, but may vary
from state to state.
In Canada, legislation in some provinces provides for
certain additional warranties or remedies other than as
stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may
not apply. This Limited Warranty provides specific legal
rights, and other rights may be available, but may vary from
province to province.
EnPak 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
Visit www.MillerWelds.com/EnPak
to locate an EnPak supplier.
Contact your Truck Equipment Distributor for:
Options and Accessories
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Always provide Model Name and Serial/Style Number.
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
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
© 2019 Miller Electric Mfg. LLC
2019−01
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising