Miller | MD430103R | Owner Manual | Miller TRAILBLAZER 302 AIR PAK User manual

Miller TRAILBLAZER 302 AIR PAK User manual
OM-229 930P
2013−10
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Battery Charging
Description
Engine Driven Welding Generator And
Air Compressor
Trailblazer 302 Air Pak
™
File: Engine Drive
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Sound Level Table − 7 Meter (23 Ft) (Reference SAE J2101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Engine Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
6-4. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Stick Scratch Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Lift-Arc TIG With Auto-Crater And Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − COMPRESSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Air Compressor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Air Compressor Gauge And Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Air Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Compressor Blow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Compressor Cold Weather Operation (Models With Air Dryer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Battery Charging Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Connecting Uninstalled Battery To Battery Charge Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Connecting Installed Battery To Battery Charge Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Setting Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Setting Battery Jump-Start Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
SECTION 10 − GENERATOR/ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Routine Generator/Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Replacing Optional Air Dryer Filter (Separator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Servicing Compressor Air Cleaner And Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-5. Changing Air Compressor Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Front Panel Display Code Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Front Panel Display Code Information For Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-6. Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7. Battery Charge/Jump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2013−09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment. Do not
test or reset GFCI receptacles at idle speed/low voltage or the
GFCI will be damaged and not provide protection from electric
shock caused by a ground fault.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
OM-229 930 Page 1
FLYING METAL or DIRT can injure
eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND
hazardous.
GASES
can
be
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
OM-229 930 Page 2
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
heating operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-229 930 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-229 930 Page 4
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
Have only qualified persons do battery charging work.
If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc,
make sure all accessories are off.
Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
Do not charge a frozen battery.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-229 930 Page 5
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-229 930 Page 6
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2013−09
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. L’électrode et le circuit de soudage sont
sous tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le
dévidoir, le logement des galets d’entraînement et
les pièces métalliques en contact avec le fil de
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
OM-229 930 Page 7
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire. Ne pas tester ni réarmer les prises femelles avec
différentiel au régime de ralenti/en basse tension: cela endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle
de protection contre une électrocution causée par un défaut de
masse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en fil
de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Pour déterminer la bonne ventilation, il est recommandé de
procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquels est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
OM-229 930 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Respecter les consignes du fabricant de la batterie pour travailler
sur une batterie ou à proximité.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Lorsque cela est nécessaire pour des travaux d entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
OM-229 930 Page 9
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes
industrielles et aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident matériel
ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air comprimé.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
OM-229 930 Page 10
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
comprimé, les branchements et les flexibles en recherchant tout
signe de détérioration, de fuite et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des
gants de soudage et des vêtements épais
pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utiliser un équipement de levage de capacité suffisante pour
lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-229 930 Page 11
LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les
modèles.
Toujours porter une protection faciale, des gants en caoutchouc
et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des
câbles de batterie, des câbles de chargeur de batterie (le cas
échéant) ou de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant
sur la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries
ou faire démarrer des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité de charge de
batterie destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Respecter les consignes du fabricant de la batterie pour
travailler sur une batterie ou à proximité.
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge,
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les
accessoires sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en
l’absence d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou
un couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position
d’arrêt avant de brancher la batterie. Veiller à ce que les pinces
de charge ne se touchent pas.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
OM-229 930 Page 12
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Des mesures de protection pour les
porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-229 930 Page 13
OM-229 930 Page 14
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
Moving parts can injure.
Safe100 2012−08
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-229 930 Page 15
A complete Parts List is available at www.MillerWelds.com
3-2. Miscellaneous Symbol Definitions
X
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
Engine Choke
Check Valve
Clearance
Battery
Engine
Read Operator’s
Manual
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Lift Arc TIG
Positive
Negative
Alternating Current
(AC)
Direct Current
(DC)
Do not switch while
welding
Remote
Receptacle
I2
Rated Welding
Current
CC
Constant
Current
Full
E
Empty
CV
Constant
Voltage
Duty Cycle
F
Circuit Protector
Single Phase Alternator
Air Compressor
Air Pressure
Protective Earth
(Ground)
Circulating Compressor Engine−
Driven Generator
with Rectifier
OM-229 930 Page 16
A
U2
Amperes
V
Conventional Load
Voltage
Engine RPM
Volts
Output
U0
Rated No−Load
Voltage (Average)
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 rear panel. Use rating label to determine rated output. For future reference,
write serial number in space provided on back cover of this manual.
4-2. Weld, Power, And Engine Specifications
Welding
Mode
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
Weld
Output Range
CC/DC
280 A, 32 V, 100%
Duty Cycle
50
10 − 300 A
CV/DC
CC/AC
300 A, 32 V, 100%
Duty Cycle
350 A, 32 V, 60%
Duty Cycle
200 A, 25 V, 60%
Duty Cycle
35
Generator
Power Rating
Continuous: 11 kVA/kW,
100/50 A,
120/240 V AC, 60 Hz,
Single-Phase,
10 − 35 V
Fuel
Capacity
Engine
12 gal (45 L)
Tank
Kohler CH-750
Air-Cooled,
Two-Cylinder,
Four-Cycle,
30 HP Gasoline
Engine w/Electronic
Governor
Peak: 13 kVA/kW
(w/Weld Contactor Off)
60
10 − 225 A
4-3. Air Compressor Specifications
Compressor Type
Air Output At 100 psi*
100% Duty Cycle
Safety Relief
Valve Setting
Pressure
31 cfm @ 3600 RPM
Rotary Screw
28 cfm @ 3000 RPM
22 cfm 2400 RPM
Range: 80−160 psi
(550−1100 kPa)
*100 psi = 690 kPa
Air Compressor
Oil Capacity*
Auto Shutoff: 165 psi
(1140 kPa)
Pressure Relief: 200 psi
(1380 kPa)
1.75 qt (1.7 L)
* Use Only Mobil 1
Synthetic ATF Oil Or
Compressor May Be
Damaged
4-4. Battery Charger Specifications
Output
Battery Charge
Jump Start
Rated Output
Output Range
Maximum Open-Circuit
Voltage (Nominal)
12 or 24 V
14/28
10 to 75 A, 12 V Charge @ 2400 rpm
10 to 75 A, 24 V Charge @ 2400 rpm
450 A, 12 V Jump Start for 1 Minute
350 A, 24 V Jump Start for 1 Minute
4-5. Sound Level Table − 7 Meter (23 Ft) (Reference SAE J2101)
Idle Speed
2400 RPM
Weld Speed
3000 RPM
3600 RPM
Air Compressor On
73.5 dB
76.4 dB
81.6 dB
Air Compressor Off
70.9 dB
N/A
77.7 dB
Weld Load
N/A
76.4 dB
81.6 dB
OM-229 930 Page 17
A complete Parts List is available at www.MillerWelds.com
4-6. Dimensions, Weights, and Operating Angles
Dimensions
Height
34−1/4 in. (870 mm)
(To Top Of Air Cleaner)
Width
20 in. (508 mm)
Depth
59−5/8 in. (1514 mm)
A
20 in. (508 mm)
B
16-1/2 in. (419 mm)
C
1-3/4 in. (44 mm)
D
6−1/16 in. (154 mm)
E
32−3/4 in. (832 mm)
F
59−5/8 in. (1514 mm)
G
13/32 in. (10 mm) Dia.
A
B
C
D
G
4 Holes
F
!
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.
E
20°
20°
Weight
20°
Without Fuel: 771 lb (350 kg)
With Fuel: 846 lb (384 kg)
20°
Engine End
Lifting Eye Weight Rating
800 426
804 951−C
1000 lb (453 kg)
4-7. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
100% Duty Cycle at 280 Amperes DC
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Continuous Welding
400
DC MIG/FCAW
350
WELDING AMPERES
300
DC STICK
250
200
AC WELD
150
100
50
0
0
10
20
30
40
50
60
% DUTY CYCLE
OM-229 930 Page 18
70
80
90
100
242 683
A complete Parts List is available at www.MillerWelds.com
4-8. Fuel Consumption Curves
A. Welding
2.25
2.00
1.75
US GAL./HR.
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50
100
150
200
250
300
350
DC WELD AMPERES AT 100% DUTY CYCLE
400
B. Auxiliary Power
2.25
2.00
US GAL./HR.
1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
2
4
6
8
10
AUXILIARY POWER IN KILOWATTS
12
C. Air Compressor
1.200
US GAL./HR.
1.000
0.800
0.600
0.400
0.200
0.000
2400
3000
ENGINE SPEED (RPM)
3600
235 701-A
OM-229 930 Page 19
A complete Parts List is available at www.MillerWelds.com
4-9. Stick And MIG Mode Volt-Ampere Curves
A. CC/DC Stick Mode
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
100
90
DC VOLTS
80
70
60
50
MAX
40
MIN
30
20
MIN DIG
MAX DIG
10
0
0
50
100
150
200 250 300
DC AMPERES
350
400
450
500
B. CC/AC STICK Mode
80
70
AC VOLTS
60
50
MAX
40
MIN
30
20
MAX DIG
10
0
MIN DIG
0
50
100
150
200
AC AMPERES
250
300
C. CV/DC MIG Mode
40
35
DC VOLTS
30
25
20
15
10
5
0
0
100
200
300
400
DC AMPERES
OM-229 930 Page 20
500
600
700
235 696-A / 235 697-A / 235 700-A
A complete Parts List is available at www.MillerWelds.com
4-10. Generator Power Curve
The AC generator power curve
shows the generator power available in amperes at the receptacles.
Tools and motors are designed to
operate within 10% of 120/240
VAC.
300
13,000 WATTS
AC VOLTS
250
200
150
100
50
0
0
20
40
60
80
100
120
140
AC AMPERES
235 695-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-229 930 Page 21
A complete Parts List is available at www.MillerWelds.com
4-11. TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/AC TIG Mode
80
70
AC VOLTS
60
50
40
MAX
MIN
30
20
10
0
0
50
100
150
200
250
AC AMPERES
B. CC/DC TIG Mode
100
90
80
DC VOLTS
70
60
50
MAX
40
30
MIN
20
10
0
0
50
100
150
200
250
300
350
DC AMPERES
235 698-A / 235 699-A
OM-229 930 Page 22
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Movement
OR
!
Do not move or operate unit
where it could tip.
!
Do not lift unit from end.
!
Do not weld on base. Welding on
base can cause fuel tank fire or
explosion. Bolt unit down using
holes provided in base.
!
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
NOTICE − Do not install unit where air
flow is restricted or engine may overheat.
Location / Airflow Clearance
See Section 4-6 for lifting eye rating.
Mounting:
!
Do not mount unit by supporting
the base only at the four mounting holes. Do not use flexible
mounts. Use cross-supports to
adequately support unit and prevent damage to base.
1
Cross-Supports
OR
18 in.
(460 mm)
18 in.
(460 mm)
18 in.
(460 mm)
Mount unit on flat surface or use crosssupports to support base.
18 in.
(460 mm)
18 in.
(460 mm)
Mounting
1
install2 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
OM-229 930 Page 23
A complete Parts List is available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
1
!
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
!
Bed liners, shipping skids,
and some running gear insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to
bare metal on the vehicle
frame as shown.
!
Use GFCI protection when
operating auxiliary equipment. If unit does not have
GFCI receptacles, use GFCIprotected extension cord.
Do not use GFCI receptacle
to power life support equipment.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
GND/PE
2
3
3
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.
rot_grnd2 2012−03 − 800 652-D
OM-229 930 Page 24
A complete Parts List is available at www.MillerWelds.com
5-3. 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
Full
Empty
Oil Check/Fill
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). Stop fueling when
fuel level reaches neck tube. Do not
top off tank. Always leave filler neck
empty to allow room for expansion.
Check fuel level on a cold engine before use each day.
To check fuel level, turn Engine Control switch to Auto Speed position.
LED’s indicate fuel level in tank.
Engine Oil
Do not
Full
Oil Fill
Full
Gasoline
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically 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 front panel meters to determine
hours until next recommended oil
change (see Section 10-1).
For cold weather starting information, see Section 6-2.
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Ref. 804 857-C / 804 951-C
OM-229 930 Page 25
A complete Parts List is available at www.MillerWelds.com
5-4. Compressor Prestart Checks
Primary
Oil Fill/
Check
Use only Mobil 1
Synthetic ATF oil.
Optional Oil
Fill/Check
Keep oil level
in threaded
area of fill
pipe.
236 200
Check all fluids daily. Compressor must be
cold and on a level surface. Unit is shipped
with oil.
Open top service door.
Rear panel and compressor radiator
removed to show compressor components.
The compressor has a high oil temperOM-229 930 Page 26
ature shutdown. High oil temperature
can be caused by low oil level or hot air
recirculation.
Screw dipstick in completely to accu-
rately check oil level.
Check oil with unit on level surface. Check
oil level at primary or optional oil fill/check
location as shown. If oil is below or at low
level indication on dipstick, add oil (see
compressor maintenance label in Section
11-3).
Use front panel meters to determine hours
until next recommended compressor oil
change (see Section 7-1).
Inspect compressor air cleaner element
and replace if dirty (see Section 11-4).
Close top service door.
A complete Parts List is available at www.MillerWelds.com
5-5. Connecting the Battery
!
+
Connect negative (−)
battery cable last.
To connect battery, open top service door.
−
Battery is most easily accessed
by removing the top cover. Connect battery, negative cable last.
Reinstalltop cover.
Do not allow the battery
cables to touch opposing terminals. When connecting the battery
cables attach the positive (+)
cable to the positive (+) battery
terminal first, followed by negative (−) cable to negative (−) battery terminal.
Never start the engine when
the cables are loose or poorly
connected to the battery terminals.
Never disconnect the battery while the engine is running.
Never use a quick battery
charger to start the engine.
Do not charge battery with
Engine Control switch On.
Always disconnect the negative (−) battery cable before
charging battery.
Tools Needed:
1/2 in.
Ref. 229 219-A / Ref. S-0756-D / 804 953-B
5-6. Installing Exhaust Pipe
!
Stop engine and let cool.
!
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 air cleaner. Do not point
exhaust pipe towards shielding gas tank (if equipped).
Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in.
804 956-B / Ref. 229 219
OM-229 930 Page 27
A complete Parts List is available at www.MillerWelds.com
5-7. Weld Output Terminals
!
Stop engine.
!
Do not connect to CC and CV
terminals at the same time.
1
2
Work Weld Output Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire (CV) Weld Output Terminal
3
For MIG welding, connect work cable
to Work terminal and wire feeder
cable to Wire (CV) terminal.
For Stick welding, connect work
cable to Work terminal and electrode
holder cable to Stick/TIG (CC)
terminal.
For TIG welding, connect work cable
to Stick/TIG (CC) terminal and electrode holder cable to Work terminal.
Tools Needed:
1
2
3/4 in.
3
804 857-C / Ref 255 585-B
5-8. Connecting To Weld Output Terminals
1
2
!
Stop engine.
!
Failure to properly connect
weld cables may cause excessive heat and start a fire,
or damage your machine.
Do not place anything between
weld cable terminal and copper
bar. Make sure that the surfaces of the weld cable terminal
and copper bar are clean.
1
6
3
2
3
4
5
6
4
5
Tools Needed:
3/4 in.
OM-229 930 Page 28
Correct Weld Cable
Connection
Incorrect Weld Cable
Connection
Weld Output Terminal
Supplied Weld Output
Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against copper bar.
803 778-B
A complete Parts List is available at www.MillerWelds.com
5-9. Selecting Weld 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
Weld Output
Terminals
!
Stop engine before
connecting to weld
output terminals.
!
Do not use worn,
damaged,
undersized, or repaired
cables.
* This
150 ft
(45 m)
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
250
2 (35)
300
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
10 − 100% Duty Cycle
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
2x4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
2x4/0
(2x120)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-K 2013−09
5-10. Remote Receptacle Information
Socket*
A
24 volts AC. Protected by supplementary protector CB4.
B
Contact closure to A completes 24 volt AC
contactor control circuit and keeps engine at Run
speed in all modes.
I
115 volts AC. Protected by supplementary protector CB3.
J
Contact closure to I completes 115 volts AC
contactor control circuit.
C
+10 volts DC output to remote control.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
G
Circuit common for 24 and 115 volts AC circuits.
K
Chassis common.
L
Remote compressor on/off (select compressor
output on front panel). Grounding pin L stops compressor.
24 VOLTS AC
A
B
K
J
115 VOLTS AC
I
H
C L N
M
D
G
E F
REMOTE
OUTPUT
CONTROL
GND
804 857-C
REMOTE
COMPRESSOR
ON/OFF
Socket Information
*The remaining sockets are not used.
OM-229 930 Page 29
A complete Parts List is available at www.MillerWelds.com
5-11. Connecting To The Air Compressor
!
Stop engine and release air
pressure before servicing
compressor.
1
Air Compressor Outlet 1/2 in.
NPT
Air Hose Routing Options
2
Use holes in the base and rear panel to route the air compressor hose
(customer supplied) from the compressor outlet to the equipment.
Compressor
outlet is shown
with a quick−connect fitting (not
supplied).
Protect hose from rubbing on sheet
metal base.
Obtain optional 50 ft (15 m) air
hose with 1/2 in. NPT swivel fitting (Miller Part No. 300 571).
1
2
804 953-A / WM Design
OM-229 930 Page 30
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Engine Controls
1
2
Ref. 804 857-C / Ref. 258 585-B
1 Engine Control Switch
Use switch to start engine, select speed,
and stop engine. In Run position, engine
runs at weld/power speed. In Auto/Speed
position, engine speed responds to the
work activity and load:
Idle
Compressor
Battery Charge
Small Stick/TIG Welding
Loads Up To 165 A
Compressor
MIG/Heavy Stick Welding
Loads
Compressor
Generator Power
2400 RPM
2400 RPM
2400 RPM
3000 RPM
3000 RPM
Battery Jump
3600 RPM
Multiple Loads
3600 RPM
To view engine speed: with engine running
and Process Selector switch in any Stick
Hot position, cycle switch from Auto Speed
to Run three times. Meters will display engine speed ± 16 RPMs. Turn machine off to
reset display.
Use switch to reset engine and compressor
oil change hours. See section 7-1.
The unit will not return to idle speed
when the remote contactor is on and
Process/Contactor switch is in any
Wire position. The unit will return to idle
speed in all other modes.
3600 RPM
3600 RPM
3600 RPM
2 Engine Choke Control
Use control to change engine air-fuel mix
when starting engine.
To Start: Pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.
If
the engine does not start, let the
engine come to a complete stop before
attempting restart.
During cold weather some gasoline en-
gines encounter difficulties that are
easily remedied. See Section 6-2 and
12-5.
To Stop: Turn Engine Control switch to Off
position.
6-2. Engine Cold Weather Operation
2
1
Ref. 258 585−B
1
Engine Control Switch Position For
Infrequently Loaded Unit
2 Engine Control Switch Position For
Frequently Loaded Unit
Carburetor Icing
Carburetor icing causes the unit to drop below the normal idle speed and then stall.
This condition occurs when the temperature is near freezing and the relative humidity is high. Ice forms on the throttle plate and
inner bore of the carburetor. The engine
typically restarts without problems but soon
stalls again.
Treat gasoline with a fuel de−icer product (isopropyl alcohol).
Place the Engine Control switch in the
Run position.
Run engine only when expecting to frequently load it.
Breather Icing
Oil breather/pulse line icing occurs in severe cold (continuously below 0F). Moisture accumulates in the oil from piston ring
blow−by if the engine is extensively idled.
This may cause vacuum line freezing, oil
breather tube freezing or ice in the carburetor. All of these cause operating problems.
Due to ice in the lines, the engine may not
restart until it is warmed to above freezing.
Load engine and reduce idle times to
prevent engine shutdowns.
Use an electric fuel pump to avoid
pulse line freezing.
Install engine cold−weather kit.
Kohler (1-800-544-2444) offers kit for cold
weather operation. The user can install kit.
Kit pulls heated air from the muffler surface
into the carburetor and shuts the cold air off.
This increases engine temperature during
operation in both idle and high speed.
When the ambient temperatures be-
come warmer (above 45_F) the air flow
will have to be returned to normal.
Synthetic Oil
For temperatures below zero, synthetic oil
improves engine starting. After the 50 hour
break−in period, the engine oil can be
switched between synthetic and non-synthetic type oils.
Do not extend the 100 hour recommended oil change interval.
In severe cold, use synthetic grades 5W20
or 5W30. See engine maintenance label for
additional information.
OM-229 930 Page 31
A complete Parts List is available at www.MillerWelds.com
6-3. Voltage/Amperage Control
1
2
3
4
Ref. 804 857-C / Ref. 229 219-C /Ref. 258 585-B
1 And 2
Displays
Displays show weld process information
(voltage and amperage) and maintenance
information (hour meter, oil change countdown, or RPM).
Meter Weld Functions: In Wire modes,
Voltmeter displays preset weld voltage
when not welding. Meters display actual
voltage and amperage when welding and
for five seconds after welding has stopped.
In Stick and TIG modes, Voltmeter reads
ON and Ammeter displays preset amperage when not welding. Meters display actual voltage and amperage when welding
OM-229 930 Page 32
and for five seconds after welding has
stopped.
See Section 12-1 for additional display
code information.
3
Voltage/Amperage Control
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.
With Process/Contactor switch in any
Stick or TIG setting, use control to adjust
amperage. With Process/Contactor
switch in any Wire position, use control to
adjust voltage. When a remote voltage/
amperage control is connected to Remote
receptacle RC4, control sets the maximum
amperage in Stick and TIG modes, but has
no effect in MIG modes.
For models with Battery Charging, control
selects charge amperage.
4
DC/Battery/AC Switch
NOTICE − Do not switch while welding or
under load.
Use switch to select DC weld output, Battery Jump or Charge, or AC weld output.
DC weld polarity is determined by weld
cable connections. Manually change weld
cables to change polarity.
A complete Parts List is available at www.MillerWelds.com
6-4. Process/Contactor Switch
1
Ref. 804 857-C / Ref. 258 585-B
1
Process/Contactor Switch
!
Weld output terminals are energized
when Process/Contactor switch is
in an Electrode Hot position and the
engine is running.
The unit will not return to idle speed
when Process/Contactor switch is in a
Wire position and the remote contactor
is on (closure between pins A and B on
remote receptacle).
Use switch to select weld process and weld
output on/off control (see Table 6-1 and
Section 5-10).
Place switch in Remote positions to turn
weld output on and off with a device connected to the remote receptacle.
Place switch in Electrode Hot positions for
weld output to be on whenever the engine
is running.
Wire Positions:
Use Wire positions for MIG welding using a
voltage sensing wire feeder (Electrode Hot)
or wire feeder using remote control.
Stick Positions:
Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.
Stick Electrode Hot:
When switch is in a Stick Electrode Hot
mode, select one of four dig settings to provide additional amperage during short arc
length conditions and help prevent electrodes from “sticking”. See Stick position
descriptions following (reading L to R):
Soft Arc (E 7018) - This setting provides a
low dig/arc force setting for smooth weld
performance. A stable weld puddle with
little arc “snap” gives excellent weld bead
appearance with minimal spatter.
Medium Soft Arc - This setting provides a
low to medium dig/arc force that gives a
slightly more fluid weld puddle, more arc
“snap”, and reduces the potential for
electrode sticking at shorter arc lengths.
Medium Stiff Arc - This setting provides
medium dig/arc force for open root vertical
up joints or joints that do not require
additional current for fit up inconsistencies.
Stiff Arc (E6010) - This setting provides a
high dig/arc force for open root vertical
down joints where additional current is
needed to compensate for tight joint fit-up
without the need to increase overall welding
current. This setting is recommended for
those who prefer a very stiff arc with 6010
electrodes. This position is also recommended for air carbon arc (CAC-A) cutting and
gouging.
Engine runs at 3600 RPM when weld-
ing with the Process/Contactor switch
in the Stiff Arc (6010) position.
Stick Remote On/Off:
When switch is in a Stick Remote On/Off
mode, select one of three settings to provide additional amperage during short arc
length conditions and help prevent electrodes from “sticking”. See Stick position
descriptions following (reading R to L):
Soft Arc (E7018) - This setting provides a
low to medium dig/arc force that gives a
slightly more fluid weld puddle, more arc
“snap”, and reduces the potential for
electrode sticking at shorter arc lengths.
Medium Arc - This setting provides medium dig/arc force for open root vertical up
joints or joints that do not require additional
current for fit up inconsistencies.
Stiff Arc (E6010) - This setting provides a
high dig/arc force for open root vertical
down joints where additional current is
needed to compensate for tight joint fit up
without the need to increase overall welding
current. This setting is recommended for
those who prefer a very stiff arc with 6010
electrodes.
The dig circuit is disabled when switch is in
Wire or TIG positions.
TIG Positions:
TIG − Remote On/Off − Use this position for
AC or DC TIG welding using remote on/off
control.
Electrode Hot − Lift-Arc™ w/Auto Crater™
TIG (DC only) - With switch in this position,
a low voltage (10 V DC) is present between
the electrode and workpiece preventing
overheating, sticking, or contamination of
the electrode (see Section 6-6) as the arc is
struck.
End the arc using the Auto-Crater feature
(see Section 6-6).
Electrode Hot − Lift-Arc™ w/Auto Stop™
TIG (DC only) - With switch in this position,
a low voltage (10 V DC) is present between
the electrode and workpiece preventing
overheating, sticking, or contamination of
the electrode (see Section 6-6) as the arc is
struck.
End the arc using the Auto-Stop feature
(see Section 6-6).
OM-229 930 Page 33
A complete Parts List is available at www.MillerWelds.com
Table 6-1. Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Electrode Hot − Wire
MIG (GMAW)
Electrode Hot
Electrode Hot − Stick
Stick (SMAW)
Select Preferred Dig
Electrode Hot
Electrode Hot − Stick
Air Carbon Arc (CAC-A) Cutting And Gouging
Select Any Dig
Electrode Hot
Electrode Hot − Lift Arc w/Auto-Crater
TIG (GTAW) Lift Arc w/Auto-Crater (GTAW) (DC Only)
Electrode Hot
Electrode Hot − Lift Arc w/Auto-Stop
TIG (GTAW) Lift Arc w/Auto-Stop (GTAW) (DC Only)
Electrode Hot
TIG − Remote On/Off
TIG (GTAW) With HF Unit, Pulsing Device, Or
Remote Control (AC or DC)
At Remote Receptacle
Stick − Remote On/Off
Stick (SMAW) With Remote On/Off
At Remote Receptacle
Wire − Wire Feeder (CV) Using
Remote
MIG (GMAW)
At Remote Receptacle
6-5.
Stick Scratch Start
With Stick selected, start arc as
follows:
1
2
3
1
2
3
OM-229 930 Page 34
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
A complete Parts List is available at www.MillerWelds.com
6-6. Lift-Arct TIG With Auto-Cratert And 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/Contactor switch.
2
Turn gas on.
1
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Auto-Crater
1
2
3
4
Arc End With Auto-Crater:
Remote control is not needed
when using Auto-Crater.
1
2
3
4
OR
While welding.
Lift torch slightly to start
Auto-Crater end (current is
reduced).
Lower torch. Weld current
ramps down.
Shielding gas continues until
shut off.
Arc End With Auto-Stop:
1
2
Arc End With Auto-Stop
1
2
3
3
While welding.
Lift torch to start Auto-Stop.
(Lift higher than that needed
to start Auto-Crater.) Arc
stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
WM Marketing
OM-229 930 Page 35
A complete Parts List is available at www.MillerWelds.com
6-7. Remote Voltage/Amperage Control
1
Remote Receptacle RC4
Connect optional remote voltage/
amperage (V/A) control to RC4
(see Section 5-10).
Use receptacle to connect remote
control or wire feeder.
When a remote voltage/amperage
control is connected to the Remote
receptacle, the Auto Sense Remote
feature
automatically
switches voltage/amperage control to the remote control (see Sections 5-10 and 6-3).
With remote voltage/amperage
control connected, weld output in
CC mode is determined by a combination of front panel and remote
control voltage/amperage settings.
In CV mode, weld output is controlled through remote control only.
1
If no remote voltage/amperage
control is connected to the Remote
receptacle, the front panel Voltage/
Amperage control adjusts voltage
and amperage.
2
3
Remote Hand Control
(Optional)
Remote Foot Control
(Optional)
Engine
runs at weld/power
speed in Wire mode whenever
a device connected to the remote receptacle makes closure between pins A and B. In
all other modes, the engine
runs at idle speed until a load is
applied.
In Example:
Process = Stick (Using Remote On/Off)
Min = 25 A CC/DC
Max = 160 A CC/DC
2
Max (160 A DC)
Min (25 A DC)
Connect Remote
V/A Control To
Remote
Receptacle RC4
Select DC Output
And Polarity (For
models with Battery
Charging, polarity is
determined by weld
cable connection to
output terminals, not
switch position.)
Set V/A Control
(Mid-Range: About 160 A)
Adjust Remote V/A Control
(Stick Welding Only)
3
Ref. 804 857-C / Ref. 258 585-B / S-0769 / S-0774
OM-229 930 Page 36
A complete Parts List is available at www.MillerWelds.com
SECTION 7 − COMPRESSOR OPERATION
7-1. Air Compressor Switch
1
O IL
500
2
Weld output
and generator power are
reduced when the air compressor is
on.
With the compressor on, weld or generator loads will cause the engine to
run at 3600 RPM.
Air Compressor Operation
1
Displays
Displays show air compressor status (on/
off), and maintenance information (hours,
oil change countdown, fault shutdown).
See Section 12-1 for additional display
code information.
2
Compressor Function Switch
Turn switch to Air Compressor CFM settings to turn compressor on. Turn switch to
Off position to turn air compressor off.
At 22 CFM, engine runs at 2400 RPM.
At 28 CFM, engine runs at 3000 RPM.
At 31 CFM, engine runs at 3600 RPM. Use
31 CFM setting for maximum air output.
To reduce moisture in the compressor
air, install optional air cooler with separator (Part No. 300 420), or desiccant
dryer (Part No. 300 690).
When the temperature inside the unit
drops below 45 (7 C), internal heaters activate to prevent air system
freeze-up.
Air Compressor Maintenance
Use switch to monitor engine and compressor maintenance requirements.
Engine Hrs position displays total engine
hours.
Engine Oil Change position displays hours
left before next oil change. Hours count
down from 100.
Compressor Hrs position displays total
compressor hours.
Compressor Oil Change position displays
hours left before next oil change. Hours
count down from 500.
Negative hours indicate time past recommended oil change.
To reset oil change hours: with engine off,
place switch in Engine or Compressor Oil
Change position and cycle Engine Control
switch between Auto/Run and Run three
times.
Battery Charge/Jump Operation
Battery
charger output is available
only when this switch is in one of the
four Charge/Jump positions AND the
DC/Battery/AC switch is in the Battery
position. Weld output is not available.
Before
connecting battery cables,
place Compressor switch in position
matching voltage of battery being
charged or jumped.
Use switch to select battery voltage. Place
DC/Battery/AC switch in Jump/Charge position.
When done move switch to Off position
and stop engine or set Process/Contactor
switch to any Remote On/Off Switch Required position. Move DC/Battery/AC
switch to a weld position.
See Section 8 for battery charging/jump
starting procedures.
Ref. 804 857-C / Ref. 255 585-A
OM-229 930 Page 37
A complete Parts List is available at www.MillerWelds.com
7-2. Air Compressor Gauge And Regulator
1
2
Ref. 804 857-C / Ref. 258 585-B / 229 807-B
!
The air pressure gauge reads the air
compressor line pressure. Air pressure in the compressor case may be
high even when the gauge reads
zero. Wait 10 minutes for compressor blow down cycle to complete before checking/adding oil or performing maintenance.
Weld output
1
2
and generator power are
reduced when the air compressor is
on.
With the compressor on, weld or generator loads will cause the engine to
run at 3600 RPM.
Air Compressor Gauge
Air Pressure Regulator
Adjust system pressure with the regulator.
Set pressure in the no-flow condition only.
To reduce engine load and allow higher
weld and generator output, set at lowest
possible pressure for the job.
Set pressure in the 80 − 100 psi
range
to operate plasma cutting equipment or
to gouge (CAC-A). Set pressure in the
100 − 125 psi range to operate pneumatic tools.
Do not set pressure above 160 psi. If
air pressure exceeds 160 psi the compressor clutch will disengage and shut
down the compressor.
Do not set pressure below 80 psi. Com-
pressor will supply 80 psi regardless of
setting below 80 psi.
See Section 7-3 for air compressor overload information.
Models With Optional Air Dryer
For best results, maintain air pressure in air
dryer using compressed air. Air dryer pressure helps “squeeze” the water from the
compressor air. Pressure in the air dryer
may drop if there is no equipment connected to the dryer, or if the connected equipment provides little restriction (load) in the
downstream air line (open air line). Plasma
cutting and CAC-A torches provide enough
restriction (load) for proper air dryer performance.
7-3. Air Compressor Overload Protection
See Section 10-5 for engine/generator overload protection.
Over Pressure Protection
Do not set air pressure above 160 psi
(1034 kPa). If air pressure exceeds
160 psi the compressor clutch will
disengage and shut down the compressor.
If the compressor shuts down due to high
pressure, use the Air Pressure regulator
to reduce the system pressure. See Section 7-2.
OVER PRES
The compressor is equipped with an
emergency relief valve that will open if
pressure reaches 200 psi (1380 kPa).
Over Temperature Protection
The
COMP TEMP
compressor is equipped with
high oil temperature shutdown. High
oil temperature can be caused by low
oil, hot air recirculation, blocked or
clogged cooler, or fan failure.
When the temperature inside the unit
drops below 45 (7 C), internal
heaters activate to prevent air system freeze-up. Ice in air system components may cause an Over Pressure condition.
Ref. 804 857-C / Ref. 258 585-B
OM-229 930 Page 38
A complete Parts List is available at www.MillerWelds.com
7-4. Compressor Blow Down
1
Blow Down Valve
To prevent foaming or sudden
release of pressure, allow 10
minutes after shutdown before
opening the compressor oil dipstick/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.
1
236 200
7-5. Compressor Cold Weather Operation (Models With Air Dryer)
NOTICE − Air dryer must be bypassed when ambient temperature
is below 32F (0C).
!
Stop engine, and let cool.
!
Disconnect battery negative
(−) cable.
!
Wait ten minutes for air pressure to release before beginning installation.
1
1/2 NPT x 1/2 JIC Adapter
2
Air Compressor Outlet
3
Compressor Outlet Nipple
4
Compressor Outlet Elbow Fitting
Disconnect compressor hose from
separator. Disconnect adapter from
outlet; retain parts for reinstallation
as needed.
1
Install nipple and elbow into outlet.
Connect compressor hose to elbow.
3
4
2
804 953-A / 804 950-A / 242 619
OM-229 930 Page 39
A complete Parts List is available at www.MillerWelds.com
SECTION 8 − BATTERY CHARGING
8-1. Battery Charging Guidelines
!
Stop welding generator engine.
!
Have only qualified persons do
battery charging work.
!
When changing battery, charging
voltage is also present at weld output terminals.
!
Do not charge a defective battery,
a battery with loose terminals, or
one having evidence of damage
such as a cracked case or cover.
!
Before charging battery, read supplied BCI Battery Service Manual
and the Safety Precautions at the
beginning of this manual.
!
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 a vehicle without a battery.
!
Disconnect cables from weld terminals before charging a battery.
Weld terminals are electrically live
during battery charging.
8-2. Connecting Uninstalled Battery To Battery Charge Receptacle
6
Battery located outside of vehicle
3
1
5
+
2
4
−
7
!
!
Stop welding generator engine.
Place Air Compressor switch in the
Off position.
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.
OM-229 930 Page 40
1
Battery Positive (+) Terminal
2
Battery Negative (−) Terminal
Obtain Battery Charge/Jumper Cable Kit
300 422 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.
A complete Parts List is available at www.MillerWelds.com
8-3. 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) charging cable to chassis or engine
block (and away from battery).
!
!
Stop welding generator 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 (−) ungrounded post of battery. Connect
charger Positive (+) cable to vehicle
chassis or engine block (and away
from battery).
1
Battery Positive (+) Terminal
2
Battery Negative (−) Terminal
Obtain Battery Charge/Jumper Cable Kit
300 422 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)
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)
If battery Positive (+) post is grounded to
chassis, connect black (Negative) battery
charging cable to battery ungrounded Negative (−) post. Connect red (Positive) 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.
If battery Negative (−) post is grounded to
chassis, connect red (Positive) battery
OM-229 930 Page 41
A complete Parts List is available at www.MillerWelds.com
8-4. Setting Battery Charge Controls
25
1
!
Have only qualified persons
charge batteries.
1
DC/Battery/AC Switch
Place switch in Jump/Charge position.
2
Air Compressor Switch
Place switch in position matching
voltage of battery being charged.
3
NOTICE − Do not change Air Compressor or DC/Battery/AC switch
position while charging battery.
3
Voltage/Amperage Control
Use control to adjust charging current between 10 and 75 amperes.
2
Use minimum setting for single
standard battery. Increase charge
amperage for multiple batteries or
larger size batteries.
Charging current automatically
stops when terminal voltage is
15 to 25 percent above required battery voltage.
Start engine and charge battery for
10 minutes. Check battery voltage.
Continue charging if necessary.
!
Stop engine when finished
charging. Stand as far from
battery as practical and disconnect charging cables
from welding generator. Remove charging cables from
battery Negative (−) cable
first.
Ref. 255 585-B
8-5. Setting Battery Jump-Start Controls
1
!
Have only qualified persons
jump batteries.
1
DC/Battery/AC Switch
Place switch in Jump/Charge position.
2
Air Compressor Switch
Place switch in position matching
voltage of battery being jumped.
NOTICE − Do not change Air Compressor or DC/Battery/AC switch
position while jumping battery.
Start engine. Attempt to start equipment with dead battery.
2
!
Stop engine when finished
charging. Stand as far from
battery as practical and disconnect charging cables
from welding generator. Remove charging cables from
battery Negative (−) cable
first.
Ref. 255 585-B
OM-229 930 Page 42
A complete Parts List is available at www.MillerWelds.com
SECTION 9 − OPERATING AUXILIARY EQUIPMENT
9-1. Generator Power Receptacles And Supplementary Protectors
1
5
4
2
3
Ref. 258 585
!
!
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.
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is
11.0 kVA/kW.
Unplug power cord before attempting to service accessories or tools.
!
Test GFCI monthly. See Section 9-2
for GFCI information and for resetting and testing procedures.
3
Supplementary Protector CB1
Generator power decreases as weld
current or air compressor output increases.
1
120/240 V 50 A AC Receptacle RC1
2
120 V 20 A AC Receptacles RC2
and RC3 (GFCI Receptacles Shown)
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.
CB1 protects receptacles RC1, RC2, and
RC3 from overload. If CB1 opens, the receptacles do not work. Place switch in On
position to reset.
4
Supplementary Protector CB2
5
Supplementary Protector CB3
CB2 protects RC2 and CB3 protects RC3
from overload. If a supplementary protector
opens, the receptacle does not work.
Press button to reset supplementary
protector. If supplementary protector
continues to open, contact Factory
Authorized Service Agent.
Combined output of all receptacles limited
to 10 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 20 A is available
at the 240 V receptacle:
2 x (120 V x 20 A) + (240 V x 25 A) = 9.6
kVA/kW
OM-229 930 Page 43
A complete Parts List is available at www.MillerWelds.com
9-2. GFCI Receptacle Information, Resetting And Testing
1
2
3
4
!
Test and reset GFCI only at Run
speed.
RotGFCI1 2012−05
!
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.
1
120 V 20 A AC GFCI Receptacle
2
GFCI Receptacle Test Button
3
GFCI Receptacle Reset Button
4
GFCI Indicator Light (LED)
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
Resetting/Testing GFCI Receptacle
!
Test GFCI monthly. See Testing
GFCI Receptacle.
!
Do not test or reset GFCI receptacles at idle speed/low voltage or
the GFCI will be damaged and not
provide protection from electric
shock caused by a ground fault.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
OM-229 930 Page 44
!
If LED blinks, stop using GFCI receptacle and have it replaced by a
Factory Authorized Service Agent.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine and operate at Run (weld/
power) speed. Press GFCI Reset button.
Reconnect equipment to GFCI receptacle.
If GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Testing GFCI Receptacles
GFCI testing must be done with engine
running at Run (weld/power) speed.
Start engine and operate at Run (weld/
power) speed.
Press the GFCI Test button. The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur:
GFCI does not trip when tested
LED blinks
GFCI does not reset.
A complete Parts List is available at www.MillerWelds.com
9-3. Simultaneous Weld And Power
This table shows simultaneous weld and power output with air compressor off.
Weld Current in Amperes
Total Power in Watts
120 V Receptacle Amperes
240 V Receptacle Amperes
300
1000
10
5
250
3500
31
15
200
5200
46
23
150
6700
60
30
100
8000
70
35
0
11,000
88
44
9-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
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
5
120V
240V
6
2
3
4
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
240V
6
5
7
Current Available in Amperes
240 V
Each 120 V Duplex
Receptacle*
Receptacle
0
5
10
15
20
25
30
35
40
20
20
20
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-229 930 Page 45
A complete Parts List is available at www.MillerWelds.com
SECTION 10 − GENERATOR/ENGINE MAINTENANCE
10-1. Maintenance Label
OM-229 930 Page 46
A complete Parts List is available at www.MillerWelds.com
10-2. Routine Generator/Engine Maintenance
Use information displayed on the Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 6-3).
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.
For Compressor Maintenance, see Section 11.
!
Recycle engine
fluids.
= Check
= Change
= Clean
Stop engine before maintaining.
See
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Every
8
Hours
Sections
5-3, 6-3
Fuel Level
Oil Level
Meters for next oil
change interval
Oil, Fuel Spills
Every
25
Hours
Sections
10-3, 10-6
Spark Arrestor Screen
(If Equipped)
Every
50
Hours
Weld Terminals
Every
100
Hours
Engine
Manual,
Sections
10-3, 10-4
Battery Terminals
Cooling System
Oil
Air Cleaner Element
Every
200
Hours
Engine
Manual,
Section
10-4
Unreadable Labels
Spark Plug Gap
Oil Filter
Every
500
Hours
Engine
Manual
Every
1000
Hours
Fuel Filter
Weld Cables
Slip Rings*
Brushes*
Valve Clearance*
OR
Inside Unit
* To be done by Factory Authorized Service Agent
NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.
OM-229 930 Page 47
A complete Parts List is available at www.MillerWelds.com
10-3. Servicing Air Cleaner
1
3
2
!
Stop engine.
!
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in. (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
!
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-229 930 Page 48
A complete Parts List is available at www.MillerWelds.com
10-4. Changing Engine Oil, Oil Filter, And Fuel Filter
!
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
!
Full
Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 5-3).
3
Fuel Filter
4
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
!
Stop engine, tighten connections as necessary, and wipe
up fuel.
With engine off and Air Compressor
switch at Engine Oil Change, reset
oil maintenance countdown by flipping Engine Control switch from
Auto Speed to Run three times.
2
3
4
1
Tools Needed:
Ref. 804 949−C / S-0842
OM-229 930 Page 49
A complete Parts List is available at www.MillerWelds.com
10-5. Overload Protection
!
Stop engine.
Open left side door.
When a circuit breaker, supplementary protector or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
1
2
Supplementary Protector CB4
Supplementary Protector CB6
CB4 protects the stator winding
supplying 24 volt AC output to Remote receptacle RC4. If CB4
opens, 24 volt AC output to RC4
stops.
CB6 protects the compressor air
line heater. If CB6 opens, the compressor air lines may freeze in cold
weather and cause a no air pressure or high air pressure condition.
Supplementary
protectors
CB1 and CB3 protect the stator
winding supplying 115 volt AC
output to Remote Receptacle
RC4 (see Section 9-1).
Press button to reset.
3
4
Fuse F6 (See Parts List)
Fuse F7 (See Parts List)
F6 and F7 protect the engine wiring
system from overload. If F6 or F7
opens, the engine will not crank.
Replace fuse if open.
Close left side door.
5
Circuit Breaker CB5 (Not
Shown)
CB5 protects the air compressor. If
CB5 opens, the air compressor
stops (the clutch and fan stop). CB5
automatically resets when the circuit breaker cools.
3
2
4
1
804 953−A / Ref. 229 219 / 161-001
OM-229 930 Page 50
A complete Parts List is available at www.MillerWelds.com
10-6. Servicing Optional Spark Arrestor
!
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in.
804 951 / Ref. 803 572−A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-229 930 Page 51
A complete Parts List is available at www.MillerWelds.com
SECTION 11 − AIR COMPRESSOR MAINTENANCE
11-1. Maintenance
!
Recycle
engine
fluids.
Stop engine before
maintaining.
See
compressor Maintenance
Label for important start-up and
service information. Service
compressor more often if used in
severe conditions.
Replace compressor oil and filter after the first 50 hours of operation.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
8
Hours
Reference
To Check Oil Level:
Sections
5-3, 7-1
Do not open dipstick until
unit has been off for 10 minutes.
Do not open while running.
Oil Level.
Every
500
Hours
Or
Yearly
= Replace
Screw dipstick fully in before checking oil level.
Meters for next oil
change interval
Fluid Spills
Section
11-4, 11-5
Oil
Oil Filter
Air/Oil Separator
Air & Control Lines For
Wear & Aging
Air Cleaner
Belt Condition/Tension
Optional Air Dryer Filter
11-2. Replacing Optional Air Dryer Filter (Separator)
!
Stop engine, and let cool.
!
Disconnect battery negative
(−) cable.
!
Pressure may remain in air
dryer system even though
gauge reads 0 psi. Release
pressure in air dryer system
by connecting hose to outlet
and waiting for pressure to
bleed off.
Replace filter annually or when air
dryer output is too low.
1
Bowl
2
Collar
3
Filter Element
2
To replace filter, push up and turn
bowl 1/4 turn counterclockwise.
Unscrew collar and remove filter.
1
Install new filter and reinstall collar
and bowl.
3
Ref. 242 619 / 804 054
OM-229 930 Page 52
A complete Parts List is available at www.MillerWelds.com
11-3. Compressor Maintenance Label
OM-229 930 Page 53
A complete Parts List is available at www.MillerWelds.com
11-4. Servicing Compressor Air Cleaner And Air/Oil Separator
!
Stop engine.
!
Wait 10 minutes for compressor
blow down cycle to complete before performing maintenance.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
damaged element is not covered by the
warranty.
1
Compressor Air Cleaner
2
Cover
3
Air Cleaner Element
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.
1
NOTICE − Do not clean element with
compressed air.
4
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.
Start engine, run air compressor, and
check for oil leaks.
!
Stop engine.
Tools Needed:
4
2
3
804 950-C
OM-229 930 Page 54
A complete Parts List is available at www.MillerWelds.com
11-5. Changing Air Compressor Oil And Filter
Tools Needed:
7/8, 15/16 in.
4
3
2
1
804 950-C / 804 951-C / 804 952-A
!
!
1
2
3
4
Stop engine and let cool.
Wait 10 minutes for compressor blow
down cycle to complete before performing maintenance.
Air Compressor Oil Filter
Air Compressor Oil Drain Hose
Air Compressor Oil Fill Cap
Air Compressor Oil Dipstick/Fill
To change compressor oil and filter:
Drain compressor oil while compressor is still
warm.
Route compressor oil drain hose through access panel on rear panel. Remove compressor oil dipstick/fill cap. Remove plug from oil
drain hose and drain oil into a suitable container. Reinstall oil drain hose plug.
Remove filter by turning filter counterclockwise. Apply thin coat of oil to gasket on new
filter. Install new filter and turn clockwise until
tight.
Add recommended oil until oil level on dipstick
shows system is full (see compressor maintenance label for oil specifications). Reinstall oil
fill cap. Hand−tighten cap to prevent pressure
release.
With engine off and Air Compressor switch at
Compressor Oil Change, reset oil maintenance countdown by flipping Engine Control
switch from Auto Speed to Run three times.
OM-229 930 Page 55
A complete Parts List is available at www.MillerWelds.com
SECTION 12 − TROUBLESHOOTING
12-1. Front Panel Display Code Information
Left Display
Right Display
Description
How/When Code Is Displayed
ON
10 − 304
Preset Weld Current
Code is displayed when engine is running, Engine Control switch is in Run
or Auto Speed position, Process/Contactor switch is in Electrode Hot −
Stick or TIG position, and Compressor switch is in Off or On positions.
0
10 − 304
Preset Weld Current
Code is displayed when engine is running, Engine Control switch is in Run
or Auto Speed position, Process/Contactor switch is in Remote − Stick or
TIG position, and Compressor switch is in Off or On positions.
13 − 35
0
Preset Weld Voltage
Code is displayed when engine is running, Engine Control switch is in Run
or Auto Speed position, Process/Contactor switch is in Electrode Hot −
Wire or Remote − Wire position, and Compressor switch is in Off or On
positions.
HRS
XXXX
Engine Or Compressor
Total Operating Hours
Code is displayed when Engine Control switch is in Run or Auto Speed
position and Compressor switch is in Engine Hours or Compressor Hours
position. (Engine need not be running to display code.)
OIL
XXX
Hours Remaining Until
Recommended Oil
Change For Engine Or
Compressor
Code is displayed when Engine Control switch is in Run or Auto Speed
position and Compressor switch is in Engine Oil Change or Compressor Oil
Change position. (Engine need not be running to display code.) Display
shows negative hours when oil change is overdue.
RPM
XXXX
Engine Speed
AIR
OFF
Code is displayed when engine is running, Process/Contactor switch is in
Electrode Hot − Stick position, and Engine Control switch is toggled
between Run and Auto Speed positions three or four times.
Air Compressor Off
Before start-up, code is displayed when Engine Control switch is in Run or
Auto Speed position and Compressor switch is in Off position. Code is also
displayed for three seconds when Compressor switch is moved to Off position while engine is running. (Display then returns to appropriate weld display.)
AIR
ON
Air Compressor On
Before start-up, code is displayed when Engine Control switch is in Run or
Auto Speed position and Compressor switch is in any On position. Code is
also displayed for three seconds when Compressor switch is moved to any
On position while engine is running. (Display then returns to appropriate
weld display.)
COMP
TEMP
Compressor
Over-Temperature
Code is displayed when compressor has stopped because compressor oil
temperature exceeded 240° F (116° C).
OVER
PRES
Compressor
Over-Pressure
Code is displayed when compressor has stopped because compressor air
pressure exceeded 170 PSI (1172 kPa).
AUTO
CAL.
Auto-Calibration
Code is displayed for about six seconds after start−up as the electronic
governor calibrates itself by running the engine at an elevated speed for a
short period. The machine provides no output until the display changes.
RE−S
TART
Restart
All Segments On
All Segments On
Bulb Test
OM-229 930 Page 56
Code is displayed when unit has stopped due to generator overload or
detection of a fault that could cause damage. Turn Engine Control switch
Off and then restart. Check all outputs and connections after restarting. If
code is displayed again have unit checked by an Authorized Service Agent.
During engine cranking all LED segments are turned on for test purposes.
Observe the displays during cranking to determine if an LED segment is
faulty.
A complete Parts List is available at www.MillerWelds.com
12-2. Front Panel Display Code Information For Battery Charger
Left Display
Right
Display
Description
How/When Code Is Displayed
JUMP
CHRG
DC/Battery/AC Switch in Jump/
Charge position
Code is displayed when Air Compressor switch is not in a battery charge or
jump position.
CHRG
10 − 75
DC/Battery/AC Switch in Jump/
Charge position
Code is displayed when Air Compressor switch is in a battery charge position. 10 − 75 displays preset maximum charge current set by V/A control.
JUMP
10 − 75
DC/Battery/AC Switch in Jump/
Charge position
Code is displayed when Air Compressor switch is in a jump position. 10 −
75 displays preset maximum charge current set by V/A control.
24V
JUMP
DC/Battery/AC Switch NOT in
Jump/Charge position
Code is displayed when Air Compressor switch is in 24 volt jump position.
24V
CHG
DC/Battery/AC Switch NOT in
Jump/Charge position
Code is displayed when Air Compressor switch is in 24 volt charge position.
12V
JUMP
DC/Battery/AC Switch NOT in
Jump/Charge position
Code is displayed when Air Compressor switch is in 12 volt jump position.
12V
CHG
DC/Battery/AC Switch NOT in
Jump/Charge position
Code is displayed when Air Compressor switch is in 12 volt charge position.
CHK
BATT
DC/Battery/AC Switch in
Jump/Charge position
Charger is detecting a fault in the set up or the battery:
Wrong voltage battery (set up for 12 volt and connect a 24 volt battery or
set up for 24 volt and connect a 12 volt battery)
Bad connection (no battery detected)
Battery is not accepting a charge (open battery cell[s]).
In JUMP 24 volt mode, charger will cycle three times when a battery is not
accepting a charge and then provide current for jump starting. In JUMP 12
volt mode the charger will go directly to providing current for Jump Starting.
OM-229 930 Page 57
A complete Parts List is available at www.MillerWelds.com
12-3. Welding Troubleshooting
Trouble
No weld output.
Remedy
Check weld control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-3 and 6-7).
Check and secure connections to Remote receptacle RC4 (see Sections 5-10).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low weld output.
Check control settings.
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-3 and 6-7).
Check and clean air cleaner as necessary (see Section 10-3).
Have Factory Authorized Service Agent check engine speed, brushes, slip rings, and circuit boards PC1
and PC2.
See engine manual.
High weld output.
Check control settings.
Have Factory Authorized Service Agent check engine speed and circuit boards PC1 and PC2.
Weld output cannot be adjusted.
Have Factory Authorized Service Agent check field current control board PC2.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to remote control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check engine speed, brushes, slip rings, and circuit boards PC1
and PC2.
Check shielding gas, ensure proper shielding gas coverage while welding.
No remote voltage/amperage control.
Check and tighten connections to Remote receptacle RC4 (see Section 5-10). Check and secure
lead connections to remote control.
No front panel voltage/amperage
control.
Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
5-10).
No 24 volt AC power output at Remote
receptacle RC4.
Reset supplementary protector CB4 (see Section 10-5).
No 115 volt AC power output at Remote receptacle RC4.
Reset supplementary protector(s) CB1 and/or CB3 (see Section 9-1).
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
OM-229 930 Page 58
A complete Parts List is available at www.MillerWelds.com
Trouble
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Remedy
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
12-4. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 9-1).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low power output.
Check and clean air cleaner as necessary.
Have Factory Authorized Service Agent check engine speed.
See engine manual.
High power output.
Have Factory Authorized Service Agent check engine speed.
Erratic power output.
Have Factory Authorized Service Agent check engine speed, brushes, slip rings, and field current control
board PC2.
Check receptacle wiring and connections.
12-5. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
Check fuses F6 and F7, and replace if open (see Section 10-5).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine does not start.
Check fuel level (see Section 5-3).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual.
See engine manual.
Engine starts but stops when Engine
Control switch returns to Auto Speed
position.
Check oil level (see Section 5-3). Low oil pressure shutdown stops engine if oil pressure is too low.
Use correct grade oil for operating temperature. (see Section 10-1).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
OM-229 930 Page 59
A complete Parts List is available at www.MillerWelds.com
Trouble
Battery discharges between uses.
Remedy
Place Engine Control switch in Off position when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine stopped during normal
operation.
Check fuel level (see Section 5-3).
Check oil level (see Section 5-3). Low oil pressure shutdown stops engine if oil pressure is too low.
Oil level too high reduces capacity of the fuel pump.
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Engine does not return to idle speed.
Be sure Engine Control switch S2 is in Auto Speed position.
Remove all weld and generator power loads.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Turn off remote device connected to Remote receptacle RC4 (see Section 5-10).
Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Auto Speed position.
Place Engine Control switch in the Run position for small loads.
During operation in near freezing temperatures, engine starts and goes to
idle but stalls after a few minutes.
Treat fuel with isopropyl alcohol de-icer product.
Place Engine Control switch in the Run position until unit has been in operation and loaded for a period of time.
During operation in severe cold weather, engine starts and goes to idle but
stalls after a few minutes.
Install engine manufacturer’s kit for cold-weather operation.
12-6. 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.
off before turning compressor on again.
Allow supplementary protector CB5 to reset. (CB5 automatically resets when it cools.) If CB5 continues
to open, contact Factory Authorized Service Agent.
Check compressor belt and tension. Be sure correct belt is used and is properly installed. Replace belt
if damaged or stretched.
Have Factory Authorized Service Agent check Air Compressor control circuit and clutch.
Air compressor stops with air demand.
Check compressor oil level (see Section 5-3). Automatic shutdown stops compressor if compressor temperature is too high.
Verify adequate air flow to compressor. Check for blocked air intake. 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.
Replace compressor oil filter (see Section 11-5).
Have Factory Authorized Service Agent check compressor cooling fan and clean compressor cooler
core. Automatic shutdown stops compressor if compressor temperature is too high.
OM-229 930 Page 60
A complete Parts List is available at www.MillerWelds.com
Trouble
Remedy
Air compressor stops after short period Check compressor oil level (see Section 5-4). Automatic shutdown stops compressor if compressor temof operation.
perature is too high.
Circuit breaker CB5 is open. CB5 automatically resets when the compressor cools. If CB5 continues to
open, contact Factory Authorized Service Agent.
Check fan operation. Fan should run whenever compressor is on. Have Factory Authorized Service
Agent check fan circuit.
Clean debris from oil cooler. 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.
Low air pressure.
Check for leaks in air lines and hoses, including control line.
Reduce air demand.
Close air outlet valve.
Check for frozen lines or hoses downstream from compressor outlet.
Adjust compressor air pressure (see Section 7-2).
Check air compressor air cleaner (see Section 11-4).
Check compressor oil level (see Section 5-4).
Check air/oil separator, and replace if plugged (see Section 11-4).
Check compressor belt and tension. Be sure correct belt is used and is properly installed. Replace belt
if damaged or stretched.
Have Factory Authorized Service Agent check compressor blow down valve, and for leaks in control
lines. Also check air compressor for rated output.
High air pressure.
Adjust compressor air pressure (see Section 7-2).
Verify control line is connected at regulator valve and inlet valve. Check for frozen control lines. If ambient
temperature is cold, run unit for a period of time to allow heaters to thaw control lines and regulator.
Check air/oil separator, and replace if plugged (see Section 11-4).
Have Factory Authorized Service Agent check for leaks in control lines, and also check air gauge, compressor air inlet valve, safety valve, air pressure switch, and internal heating system.
Insufficient air delivery.
Check air compressor air cleaner (see Section 11-4).
Check air/oil separator, and replace if plugged (see Section 11-4).
Check for frozen lines or hoses downstream from compressor outlet.
Have Factory Authorized Service Agent check engine speed, and adjust if necessary.
Check compressor belt and tension. Be sure correct belt is used and is properly installed. Replace belt
if damaged or stretched.
Have Factory Authorized Service Agent check compressor air inlet valve, safety valve, air pressure
switch, and internal heating system.
Oil in air from compressor.
Check compressor oil level (see Section 5-4). 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 11-4).
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.
Check connections of control lines.
Have Factory Authorized Service Agent check for plugged oil scavenge line.
Air compressor overheats.
Check compressor oil level (see Section 5-3). Automatic shutdown stops compressor if compressor temperature is too high.
Verify adequate air flow to compressor. Check for blocked air intake. 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.
Verify compressor fan is running while compressor is on. Contact Factory Authorized Service Agent if
fan is not operating properly.
OM-229 930 Page 61
A complete Parts List is available at www.MillerWelds.com
Trouble
Remedy
Air compressor overheats (continued)
Adjust compressor air pressure (see Section 7-2).
Replace compressor oil filter (see Section 11-5).
Have Factory Authorized Service Agent check cooling fan. Automatic shutdown stops compressor if
compressor temperature is too high.
Have Factory Authorized Service Agent check thermal valve element, and replace if necessary.
Have Factory Authorized Service Agent clean compressor cooler core.
Oil in compressor air cleaner.
Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.
Water in compressor oil.
Operate air compressor at 3600 rpm to remove water.
If oil appears milky, change oil, oil filter, and air/oil separator.
Moisture in compressor air.
Install optional air cooler with separator (Part No. 300 420), or desiccant dryer (Part No. 195 117).
System retains pressure after shutdown. Have Factory Authorized Service Agent check compressor blow down valve, and leak back from airline.
12-7. Battery Charge/Jump Troubleshooting
Trouble
Remedy
No battery charge/jump output.
Be sure DC/Battery/AC switch is in Jump/Charge position.
Be sure Compressor switch is in a Jump or Charge position.
Be sure battery is connected.
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.
Decrease Voltage/Amperage control setting.
SECTION 13 − PARTS LIST
13-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
. . . . . . . . . . . F6 . . . . . 021718
. . . . . . . . . . . F7 . . . . . 242712
. . . . . . . . . . . . . . . . . . . . 238743
. . . . . . . . . . . . . . . . . . . . 238744
. . . . . . . . . . . . . . . . . . . . 238745
. . . . . . . . . . . . . . . . . . . . 066698
. . . . . . . . . . . . . . . . . . . . 215985
. . . . . . . . . . . . . . . . . . . . 238746
. . . . . . . . . . . . . . . . . . . . 232207
. . . . . . . . . . . . . . . . . . . . 232208
. . . . . . . . . . . . . . . . . . . . 232209
. . . . . . . . . . . . . . . . . . . . 250892
. . . . . . . . . . . . . . . . . . ♦203877
♦OPTIONAL
Description
Quantity
. . Fuse, Mintr Gl 30 Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuse, 15 Amp Automotive Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter, Kohler Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, Fuel w/Clamps & 1/4 in Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Oil Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Inlet Air Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Separator, Oil/Air Rotary Screw Compressor . . . . . . . . . . . . . . . . . . . . . . .
. . Belt, Drive AirPak 6 Rib Poly V K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Element, Filter 5 Micron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.
OM-229 930 Page 62
A complete Parts List is available at www.MillerWelds.com
Notes
OM-229 930 Page 63
SECTION 14 − ELECTRICAL DIAGRAMS
Figure 14-1. Circuit Diagram For Welding Generator
OM-229 930 Page 64
256 536-B
OM-229 930 Page 65
SECTION 15 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
15-1. 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 2012−03 − ST-800 577
15-2. 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-229 930 Page 66
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
welding 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.
15-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
3
GND/PE
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
15-4. 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 15-8).
VOLTS 115
AMPS 4.5
Hz
60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-229 930 Page 67
15-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
15-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-229 930 Page 68
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
15-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-229 930 Page 69
15-8. 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).
Welding 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
15-9. 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-229 930 Page 70
15-10. 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.
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 Welding 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 15-4).
OM-229 930 Page 71
15-11. 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 (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Use GFCI protection when operating auxiliary equipment. 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 (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-229 930 Page 72
6
Notes
OM-229 930 Page 73
Notes
OM-229 930 Page 74
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed one year after
the equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* Load Banks
* Motor Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2013-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2013 Miller Electric Mfg. Co.
2013−01
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