Miller | MJ280348R | Owner Manual | Miller TRAILBLAZER 325 DIESEL WITH ARCREACH User manual

Miller TRAILBLAZER 325 DIESEL WITH ARCREACH User manual
OM-279836F
2018−06
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
Description
Engine Driven Welder/Generator
Trailblazer 325 Diesel
®
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Engine Drive
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
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2017−06
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 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Overview And Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
TABLE OF CONTENTS
SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Engine Auto Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Lift-Arc TIG With Auto-Stop And Auto-Crater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Associating ArcReach Devices (ArcReach Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Optional Excel Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Engine Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Replacing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2018−01
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
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!
Stop engine on inverter and discharge input capacitors according
to instructions in Manual before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-279836 Page 1
FLYING METAL or DIRT can injure
eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND
hazardous.
GASES
can
be
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
OM-279836 Page 2
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-279836 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use correct procedures and equipment of adequate capacity to
lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-279836 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.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
Have only qualified persons do battery charging work.
If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc,
make sure all accessories are off.
Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
Do not charge a frozen battery.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
HIGH PRESSURE FLUIDS can injure or kill.
Engine fuel system components can be under
high pressure.
Before working on fuel system, turn off engine
to release pressure.
If any fluid is injected into the skin or body seek medical help immediately.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with electronic equipment
perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-279836 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
Always start and operate the engine in a well−ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
For Standards regulating hydraulic systems, contact the National Fluid
Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
WI 53214 (phone: (414) 778-3344, website: www.nfpa.com).
Battery Service Manual, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.batterycouncil.org).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-279836 Page 6
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2018−01_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. L’électrode et le circuit de soudage sont
sous tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le
dévidoir, le logement des galets d’entraînement et
les pièces métalliques en contact avec le fil de
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
d’une tension de circuit−ouvert double.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
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.
OM-279836 Page 7
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Arrêtez le moteur sur l’onduleur et déchargez les condensateurs
d’entrée conformément aux instructions du manuel avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en fil
de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
OM-279836 Page 8
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).
Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
recouvrements et dispositifs de protection.
panneaux,
Arrêter le moteur avant d’installer ou brancher l’appareil.
Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-279836 Page 9
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes
industrielles et aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident matériel
ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air comprimé.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
OM-279836 Page 10
MÉTAL CHAUD provenant du découpage
ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
comprimé, les branchements et les flexibles en recherchant tout
signe de détérioration, de fuite et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES
PIÈCES
CHAUDES
peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement avant
d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les
modèles.
Toujours porter une protection faciale, des gants en caoutchouc
et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
OM-279836 Page 11
Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus
d’informations.
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge,
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les accessoires
sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en
l’absence d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge
ne se touchent pas.
Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.
Les composants du système d’alimentation
peuvent contenir du carburant sous pression
élevée.
Avant d’intervenir sur le système d’alimentation de carburant,
arrêter le moteur pour dépressuriser le système.
En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
OM-279836 Page 12
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-6. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Pour les moteurs diesel :
AVERTISSEMENT : les gaz d’échappement de moteurs diesel
vous exposent à des produits chimiques, reconnus par l’État
de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
Si la zone est fermée, diriger l’échappement vers l’extérieur.
Ne pas modifier ni altérer le système d’échappement.
Ne pas faire tourner le moteur au ralenti, sauf si nécessaire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West
Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
778-3344, site web : www.nfpa.com).
Manuel de service de batterie, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
1-312-245-1074, site Web : www.batterycouncil.org).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: par exemple, des restrictions
d’accès pour les passants ou une évaluation individuelle des risques
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-279836 Page 13
OM-279836 Page 14
Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbol Definition
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2017−04
Moving parts can injure.
Safe100 2012−08
Never use generator inside a home or garage, even if doors and windows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
3-2. Miscellaneous Symbol Definitions
A
V
X
h
Amperage
Negative
Shielded Metal
Arc Welding
(SMAW)
Voltage
Positive
Gas Metal Arc
Welding (GMAW)
Hertz
Direct Current
(DC)
Flux Cored Arc
Welding (FCAW)
Duty Cycle
Alternating
Current (AC)
Hours
Protective Earth
(Ground)
Circuit Breaker
Seconds
U0
U2
I2
Rated No−Load
Voltage (OCV)
Supplementary
Protector
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Touch Start
(GTAW)
Clock, Time
Switch
Output
Engine Oil
Conventional
Load Voltage
Read Operator’s
Manual
Rated Welding
Current
OM-279836 Page 15
Complete Parts List available at www.MillerWelds.com
Notes
OM-279836 Page 16
Fuel
Idle (Slow)
Battery (Engine)
Run (Fast)
Air Filter
Output On
Engine
Remote
Engine
Belt Drive
Engine Start
(Engine RPM)
Temperature
Engine Stop
Engine Coolant
Temperature
Glow Plug
Check Valve
Clearance
Engine−Driven
3−Phase
Alternator with
Rectifier
Single Phase
Alternator
Arc Control
USB
Push Button
Rotating Knob
And Push Button
Air Carbon Arc
Cutting (CAC-A)
Complete Parts List available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Weld, Power, and Engine Specifications
This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Welding
Mode
Rated Welding
Output
Maximum
Open-Circuit
Voltage
Weld Output
Range
CC/DC
325 A, 33 V, 100%
Duty Cycle
100
10 − 325 A
325 A, 33 V, 100%
Duty Cycle
100
CV/DC
13 − 35 V,
10−325 A
Generator Power
Rating
Continuous: 10.5 kVA/
kW, 88/44 A,
120/240 V AC, 60 Hz,
Single-Phase,
Fuel Capacity
Engine
12 gal (45 L)
Tank
Kubota D902
Water-Cooled,
Three-Cylinder,
Four-Cycle,
24.8 HP
Diesel Engine
Peak: 12 kVA/kW
4-3. Environmental Specifications
A. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
−20 to 104°F (−29 to 40°C)
−40 to 131°F (−40 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
Notes
OM-279836 Page 17
Complete Parts List available at www.MillerWelds.com
4-4. Dimensions, Weights, And Operating Angles
!
Do not exceed tilt angles or
engine could be damaged or
unit could tip.
!
Do not move or operate unit
where it could tip.
Weight: 638 lb (289 kg)
Lifting Eye Weight
Rating: 1250 lb (567 kg)
Support Assembly Dimensions
259 701 / 259 702
OM-279836 Page 18
Complete Parts List available at www.MillerWelds.com
4-5. Duty Cycle And Overheating
1
1
100% Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
This unit is rated at 325 amperes
DC for continuous welding.
NOTICE − Exceeding duty cycle can
damage unit and void warranty.
260 048-A
OM-279836 Page 19
Complete Parts List available at www.MillerWelds.com
4-6. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator.
A. Stick
CC/DC XX10 Electrode
100
90
80
70
VOLTS
60
50
40
30
20
30 A 10
0
0
50
150 A Soft 25
100
150
150 A 150 A Stiff 25
200
250
AMPERES
300
350
325 A 400
450
CC/DC XX18 Electrode
100
90
80
70
VOLTS
60
50
40
30
20
10
30 A 0
0
50
150 A Soft 25
100
150
150 A 200
250
AMPERES
150 A Stiff 25
300
350
325 A 400
450
257 137
OM-279836 Page 20
Complete Parts List available at www.MillerWelds.com
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator.
B. MIG
100
90
80
70
VOLTS
60
50
40
35 Volts
30
25 Volts
20
13 Volts
10
0
0
50
100
150
200
250
300
350
400
AMPERES
C. TIG
100
90
80
70
VOLTS
60
50
40
30
325 Amps
20
150 Amps
10 Amps
10
0
0
50
100
150
200
250
300
350
AMPERES
257 137
OM-279836 Page 21
Complete Parts List available at www.MillerWelds.com
4-7. Fuel Consumption
On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect about 24 hours of operation.
Welding at 150 amps at 40% duty
cycle uses approximately 1/2 gallon per hour, or about 22 hours of
operation.
1.50
1.25
US Gal./Hr.
1.00
0.75
0.50
0.25
IDLE
0.00
0
50
100
150
200
250
300
350
DC Weld Amperes At 100% Duty Cycle
2.00
1.75
1.50
US Gal./Hr.
1.25
1.00
0.75
0.50
EXCEL POWER
0.25
IDLE
0.00
0
1
2
3
4
5
6
7
8
9
10
Aux Power KiloWatts at 100% Duty Cycle
282449-A / 283005-A
OM-279836 Page 22
Complete Parts List available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welder/Generator
Movement
OR
!
Do not move or operate unit
where it could tip.
!
Do not lift unit from end.
!
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
!
Always securely fasten welder/
generator onto transport vehicle or trailer and comply with
all DOT and other applicable
codes.
NOTICE − Do not install unit where air
flow is restricted or engine may overheat.
See Section 4-4 for lifting eye rating.
Location / Airflow Clearance
Mounting:
18 in
(460 mm)
18 in
(460 mm)
Do not mount unit by supporting the base only at the four
mounting holes. Do not use
flexible mounts. Use crosssupports to adequately support unit and prevent damage
to base.
1
Cross-Supports
OR
OR
18 in
(460 mm)
!
Mount unit on flat surface or use
cross-supports to support base.
18 in
(460 mm)
Go to MillerWelds.com for more
information on truck installations.
18 in
(460 mm)
Mounting
1
install2 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
OM-279836 Page 23
Complete Parts List available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
rot_grnd2 2018−01 − 800652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
!
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
1
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
2
3
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-3. Installing Exhaust Pipe
!
Stop engine and let cool.
!
Do not blow exhaust toward
right side of unit where air inlet
is or air cleaner may need to be
replaced more often. Point exhaust pipe in desired direction
but always away from front
panel and direction of travel.
1
2
Exhaust Pipe
Exhaust Pipe Clamp
Tools Needed:
9/16 in. Or 14 mm
Slide clamp over muffler pipe. Slide
exhaust pipe onto muffler pipe and rotate exhaust pipe to desired position.
Secure exhaust pipe with clamp.
1
2
259 703
OM-279836 Page 24
Complete Parts List available at www.MillerWelds.com
5-4. Connecting the Battery
+
−
Tools Needed:
3/8, 1/2 in.
259 707 / Ref. S-0756-D
!
Connect negative (−) cable last.
Battery is most easily accessed through
the rear panel. Remove battery access
panel from rear panel. Connect battery,
negative cable last. Reinstall battery access panel.
Do not allow the battery cables to
touch opposing terminals. When connect-
ing the battery cables attach the positive
(+) cable to the positive (+) battery terminal first, followed by negative (−) cable to
negative (−) battery terminal.
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.
Notes
OM-279836 Page 25
Complete Parts List available at www.MillerWelds.com
5-5.
Overview And Engine Prestart Checks
7
4
5
6
3
2
11
10
9
8
1
1
2
3
4
5
6
Generator Power Receptacles (see
Section 7-1)
Weld Output Terminals (see Section 5-6)
Operator Controls (see Section 6)
Voltmeter And Ammeter Displays
Fuel Level Indicators
Fuel Filler Cap
OM-279836 Page 26
7
Exhaust Pipe
13 Coolant Overflow Bottle
8
Oil Fill Cap
14 Oil Filter
9
Water Bypass Hose
15 Oil Dipstick
10 Radiator Cap
16 Air Filter
11 Engine Maintenance Label
17 Inline Fuel Filter
12 Oil Drain Location
18 Fuel Filter
Complete Parts List available at www.MillerWelds.com
!
Engine Left Side
Engine shown with doors removed. Doors must be in place when
engine is running.
Engine must be cold and on a level surface. See maintenance label (Section 8-3)
for fluid specifications.
Starting engine for the first time:
Add fresh fuel to bottom of filler neck.
14
If coolant level is not visible in the filler tee,
add coolant to overflow bottle.
15
Daily pre-start checks:
Add fresh fuel to bottom of filler neck.
Check oil. If oil is not up to full mark on dipstick, add oil. Unit is shipped with 10W30
engine oil.
Check coolant level in overflow bottle. If
coolant is below Low level, add coolant until level in tank is between Low and Full levels. If overflow bottle coolant level was low,
check coolant level in radiator (see Section 8-3).
Engine damage can result from:
Low oil level
High engine temperature
Incorrect coolant mixture
Running out of fuel (air in fuel lines)
Using gasoline
Using ether or other starting fluids to
start engine
12
13
Engine stops if oil pressure is low, engine
coolant temperature is high, or fuel level is
low. Some conditions may cause engine
damage before the engine shuts down.
Oil: Check oil level often and do not use
the oil pressure shutdown system to monitor oil level.
18
17
Engine Temperature: Incorrect engine
temperature can damage engine. Do not
run engine without a properly working thermostat and radiator cap.
Keep radiator and air intake clean.
Coolant: A solution of 50% ethylene glycol base antifreeze and 50% water must
be used in this engine. Do not use 100%
antifreeze or severe damage will occur.
Fuel: Engine will shut down if fuel level is
low. Air in the fuel system causes starting
problems.
Do not use gasoline. Using ether or other
starting fluids voids warranty.
To improve cold weather starting:
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather.
16
Engine Right Side
907755
OM-279836 Page 27
Complete Parts List available at www.MillerWelds.com
5-6. Weld Output Terminals
!
Stop engine.
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged,
undersized, or repaired
cables.
1
Positive (+) Weld Output
Terminal
Stick/TIG/Gouge Negative
(−) Weld Output Terminal
Wire Negative (−) Weld
Output Terminal
2
3
For MIG welding, connect work
cable to Negative (−) terminal and
wire feeder cable to Positive (+)
terminal.
For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Positive
(+) terminal.
For TIG welding, connect work
cable to Positive (+) terminal and
electrode holder cable to Negative
(−) terminal.
1
3
2
277086-A
OM-279836 Page 28
Complete Parts List available at www.MillerWelds.com
5-7. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
10 − 60%
Duty
Cycle
Welding
Amperes
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
5-8. Connecting To Weld Output Terminals
!
Stop engine.
!
Failure to properly connect
weld cables may cause excessive heat and start a fire,
or damage your machine.
Tools Needed:
3/4 in.
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
2
1
2
6
3
3
4
5
6
Correct Weld Cable
Connection
Incorrect Weld Cable
Connection
Weld Output Terminal
Supplied Weld Output
Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against copper bar.
4
5
803 778-B
OM-279836 Page 29
Complete Parts List available at www.MillerWelds.com
5-9. Remote Receptacle Information
A
B
K
J
Socket*
I
H
C L N
D M
G
E F
*The remaining sockets are not used.
Notes
OM-279836 Page 30
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 Wire modes.
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 volts AC circuits.
K
Chassis common.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
GND
Socket Information
Complete Parts List available at www.MillerWelds.com
Notes
OM-279836 Page 31
Complete Parts List available at www.MillerWelds.com
SECTION 6 − OPERATING WELDER/GENERATOR
6-1. Front Panel Controls (See Section 6-2)
6
12
8
13
9
7
14
11
10
5
2
4
3
1
277045-B
OM-279836 Page 32
Complete Parts List available at www.MillerWelds.com
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
1
Preheat Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions
following).
2
Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Auto-Speed position, engine runs at
idle speed at no load and weld speed with load
applied.
To check engine hours when engine is
not running, turn Engine Control switch to
Run position. To check remaining oil
change hours when engine is not running, turn Engine Control switch to Auto-Speed position.
For
best performance when welding
above 300 amperes, place Engine Control switch in Run position.
NOTICE − Diesel engines in Miller equipment
are meant to operate optimally at moderate to
rated load. Using light or no load for extended
periods of time may cause wetstacking or engine damage.
To Start:
NOTICE − Do not use ether or other starting
fluids. Using starting fluids voids warranty.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325F (05C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325F (05C): turn engine control switch
to Run position. Push Preheat switch up for 6
seconds. Turn Engine Control switch to Start.
Release Engine Control switch and Preheat
switch when engine starts.
Do not operate Preheat switch for more
than 20 seconds at a time.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges, Meters, And Lights
See Section 6-12 for complete fuel, hour,
and engine shutdown information.
3
Fuel Gauge
Use gauge to check fuel level.
4
Engine Service Indicator Lights
Notifies user that engine oil service is due.
Upper LED illuminates when engine oil
change hours are between 49−1. Lower LED
illuminates when oil change hours are 0 or
less.
Weld Controls
5 Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
When a remote control is connected to the
Remote receptacle, the Auto Remote Sense
(ARS) feature automatically switches voltage/amperage control to the remote control
(see Section 6-9).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage
settings.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and
amperage.
If a remote device connected to Remote
Receptacle is faulty or is disconnected
during operation, the meters display
CHEK REMT (see Section 8-7). Clear
fault by stopping and restarting the unit or
by turning Process/Contactor switch to
another position.
6 Process/Contactor Switch
See Section 6-4 for Process/Contactor
switch information.
7 Adjust Control/Select Button
Adjust Control
With Process/Contactor Switch in any SMAW
or GTAW process, turn Adjust control to adjust preset amperage. With Process/Contactor switch in any FCAW or GMAW process,
turn Adjust control to adjust preset voltage.
Select Button
Push the control to use as Select button.
To access Arc Control setting, push and
9
DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays average weld amperage and then
defaults to preset amperage.
10 Arc Control Meter
Displays current Arc Control setting. Default
value for all processes is 0. Arc Control settings adjust: DIG for SMAW processes, Auto
Stop for GTAW processes, and inductance
for FCAW and GMAW processes. For softer
settings, the LEDs to the left of the star illuminate. For stiffer settings, the LEDs to the right
of the star illuminate. No Arc Control settings
are accessible for GTAW Remote and CAC-A
processes. See Section 6-6.
Other Receptacles
11 USB Receptacle
Allows software updates from a USB drive
(see Section 6-10). A summary file of recoded
data from the unit will be saved to a USB drive
that is inserted (see Section 6-11).
Indicator Lights
12 Setup Light
Illuminates when in the Service Menu.
13 In Use Light
Illuminates when connected to an ArcReach
accessory.
14 Arc Control Light
Illuminates when in the Arc Control settings.
hold Adjust control for 1 second, then release. Rotate counterclockwise to set
softer arc control. Rotate clockwise to set
stiffer arc control. Push Adjust control in
and release to save Arc Control setting.
Arc Control setting will time out after 5
seconds of inactivity.
To access Service Menu, push and hold
Adjust control for 5 seconds, then release. See Section 6-5 for Service Menu
operation. Service Menu will time out after 5 seconds of inactivity.
Weld Meters
Weld meters also work in combination to
display troubleshooting error codes (see
Section 8-7).
8 DC Voltmeter
Voltmeter displays preset voltage (GMAW/
FCAW welding) with contactor off, and actual
output voltage with the contactor on. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due
to resistance of cable and connections.
To set voltage, turn Process/Contactor switch
to GMAW or FCAW position. Turn V/A control
until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter
displays average weld voltage and then defaults to preset voltage.
Glow Plug Time
Above 68°F (20°C)
68 to 32°F (20 to 0°C)
Below 32°F (0°C)
t
0 seconds
5 seconds
10 seconds
Do not use glow plugs longer than
20 seconds.
Do not use ether or other starting
fluids to start engine. Using starting fluids voids warranty.
OM-279836 Page 33
Complete Parts List available at www.MillerWelds.com
6-3. Process/Contactor Switch
1
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the
engine is running.
Use switch to select weld process
and weld output on/off control (see
table below).
Place switch in Remote On/Off
Switch Required positions to turn
weld output on and off with a device
connected
to
the
Remote
receptacle.
Place switch in Electrode Hot positions for weld output to be on whenever the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Section
6-8).
Process/Contactor
switch
must be set to Output On for
ArcReach accessories to bind.
Ref. 277091-A / 280016
REMOTE ON/OFF REQUIRED
OUTPUT ON
Process/Contactor Switch Setting
Typical Process Applications (DC Only)
Output On – GMAW/FCAW (MIG)
MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not
require a control cable back to the welder/generator.
Output On – FCAW-S (Electrode
Negative)
FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that
does not require a control cable back to the welder/generator.
Output On − SMAW (STICK XX18
and STICK XX10)
Stick welding with or without a remote amperage control. Strike an arc to start welding.
Output On – GTAW (Lift-Arc TIG)
Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
welder/generator to aid arc start. Can be used with or without a remote control. Auto
Crater option can be enabled/disabled using the Service Menu (see Section 6-5).
Output On – CAC-A (Air Carbon Arc
Gouging)
Gouging with or without a remote amperage control. Strike an arc to start gouging.
Remote ON/OFF Required - GTAW
(Remote TIG)
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote control allows remote On/Off and Amperage control. Another typical application is a
simple TIG rig with a remote control device.
Remote ON/OFF Required - SMAW
(Remote Stick)
Stick welding with RHC-14 control allows remote On/Off and Amperage control. This can
help eliminate accidental arc strikes.
Remote ON/OFF Required - GMAW/
FCAW (Remote MIG)
MIG solid wire and dual shield flux core using a constant speed feeder. Use feeders with
14-pin remote voltage control, or use a Spoolmatic 30A with WC24 control.
OM-279836 Page 34
Complete Parts List available at www.MillerWelds.com
6-4. Engine Auto Speed
Approximate Amperage/RPM Steps:
0 to 135 amps: 1800 RPM
136 to 180 amps: 2400 RPM
181 to 210 amps: 2800 RPM
211 to 235 amps: 3200 RPM
235 amps and above: 3600 RPM
TIG (Lift-Arc): 1800 RPM idle
TIG (Scratch Start): 1800 RPM idle
Stick (EXX18): 1800 RPM idle
Other processes: 2400 RPM idle
Engine returns to idle about 3 seconds after
the arc is broken if running at less than 2800
RPM. If running at more than 3200 RPM, return to idle time is about 9 seconds.
Engine Auto Speed
When Engine Control switch is in Auto
Speed position, the engine speed varies
depending on the welding load and Process/Contactor switch position.
For Gouge, the engine runs at 3600 RPM
and will return to idle about 9 seconds after
the arc is broken.
For Stick, based on preset, unit goes to the
next highest speed upon arc initiation and
transitions down one speed if power is appropriate for load.
For TIG, based on preset, unit goes to
speed appropriate for load at arc initiation.
For Solid Wire, unit goes to 3200 RPM upon arc initiation and transitions down to appropriate speed for load.
Amperage/RPM Steps and return to idle are
the same as Stick/TIG.
For Flux-Core Wire, unit goes to 3600
RPM upon arc initiation and transitions
down to appropriate speed for load.
Amperage/RPM Steps and return to idle are
the same as Stick/TIG.
Miller recommends Hobart filler metals.
6-5. Service Menu
1
Adjust Control/Select Button
Press and hold control for 5 seconds,
then release to access the Service
Menu. Rotate the knob to scroll
through the menu items. Press and
release the control to access the options and information within each
menu item.
Rotate the control counterclockwise
to decrease the value or select NO/
OFF. Rotate the control clockwise to
increase the value or select YES/
ON.
Press and release control to save selection. After 5 seconds of inactivity,
the menu will time out and the selection will not be saved.
1
Ref. 907755
Menu Item
Selectable Item
Option(s)
Description
HOT STRT
LIMT OFF
Disables Hot Start option.
(Only accessible in SMAW
processes)
LIMT 1.25
Sets Hot Start current limit, selectable between 1.25 and 2.0 (0.25 increments) in
SMAW XX10 and SMAW Remote.
LIMT 1.50
Sets Hot Start current limit, selectable between 1.5 and 3.0 (0.5 increments) in
SMAW XX18.
AUTO CRTR
ATCR ON
Enables Auto Crater option.
(Only accessible in GTAW
processes)
ATCR OFF
Disables Auto Crater option.
HOUR MTR
−−
Displays engine hours.
OIL HOUR
−−
Displays remaining oil change hours before service is due.
OIL SET
50 HRS
Sets the starting hours for oil change period. Selectable from 50−1500 hours in
50 hour increments.
OIL RSET
RSET YES
Resets oil change period to selected value. Unit is set to factory recommended
period per engine manufacturer.
RSET NO
Oil change remaining hours do not reset.
VRD ON
Enables VRD (Voltage Reducing Device) option, lowering open-circuit voltage.
VRD
VRD OFF
Disables VRD (Voltage Reducing Device) option.
SOFT WARE
−−
Displays the current revision of firmware installed.
FACT RSET
RSET YES
Resets all settings to factory defaults.
RSET NO
All settings remain at previous settings.
OM-279836 Page 35
Complete Parts List available at www.MillerWelds.com
6-6. Arc Control Settings
Arc Control is not active when the Process/Contactor switch is in the following positions:
Electrode Hot − CAC-A (Air Carbon Arc Gouging)
Remote ON/OFF GTAW (Remote TIG)
Miller recommends Hobart filler metals.
Process/Contactor Switch
Arc Control
SOFT
Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT
-12
(0)
Starting point for mild steel wire
STIFF
(1 to 25)
Starting point for aluminum wire (low inductance)
STIF
12
Voltage sensing feeder
SOFT
Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)
(0)
Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes
STIFF
(1 to 25)
Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13
electrodes. Also for pipe welding with XX10 and XX18 electrodes
SOFT
Softer, more slowly responding arc
(−25 to −1)
(0)
Starting point for XX10 electrode/open root vertical down joint
STIFF
(1 to 25)
Stiffer, more rapidly responding arc
STOP
(−5 to −1)
Auto-Crater off (see Section 6-5). More sensitive Auto-Stop
(0)
Starting point.
STOP
(1 to 5)
Less sensitive Auto-Stop
Lift-Arc start. No Auto Crater allows full control on pipe welds with
short or long arc length. Auto Stop feature allows arc to be broken
without loss of shielding gas.
OM-279836 Page 36
Complete Parts List available at www.MillerWelds.com
Process/Contactor Switch
Arc Control
STOP
(−5 to −1)
Auto Crater on (see Section 6-5). More sensitive Auto-Crater
initiation
(0)
Starting point
STOP
(1 to 5)
Less sensitive Auto-Crater initiation
SOFT
(−25 to −1)
(0)
Starting point
STIFF
(1 to 25)
SOFT
Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)
SOFT
(0)
-22
Starting point for XX10, XX11, XX13, XX14, XX24, and XX22
electrodes
STIFF
(1 to 25)
SOFT
Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT
Wire feeder connects to
Remote receptacle
-12
(0)
Starting point for mild steel wire
STIFF
(1 to 25)
Starting point for aluminum wire (low inductance).
STIF
12
Starting point for dual shield flux core, vertical overhead
STIF
25
OM-279836 Page 37
Complete Parts List available at www.MillerWelds.com
6-7.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
1
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted too high. If
electrode sticks to workpiece, use a
quick twist to free it.
2
Miller recommends Hobart filler
metals.
3
6-8. Lift-Arct TIG With Auto-Stopt And Auto-Cratert
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-Stop
1
2
3
See
Section 6-5 to adjust
Auto-Stop and Auto-Crater.
Arc End With Auto-Stop:
1
2
3
While welding.
Lift torch to start Auto-Stop.
Arc stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
Arc End With Auto-Crater:
OR
Remote control is not needed
when using Auto-Crater.
Arc End With Auto-Crater
1
2
3
4
1
2
3
4
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.
Miller
recommends Hobart
filler metals.
WM Marketing
OM-279836 Page 38
Complete Parts List available at www.MillerWelds.com
6-9. Remote Voltage/Amperage Control
1
Remote Receptacle RC4
Connect optional remote voltage/
amperage (V/A) control to RC4
(see Section 5-9).
2
1
Process/Contactor Switch
With remote control connected,
weld output in Stick or TIG is determined by a combination of front
panel and remote control voltage/
amperage settings. In Wire, weld
output is controlled through remote
control only.
2
In Example:
Process = Stick (Using Remote On/Off)
Min = 30 A CC/DC
Max = 160 A CC/DC
OR
Max (160 A DC)
Min (30 A DC)
Connect Remote
V/A Control To Remote Receptacle
RC4
Set Process
Set V/A Control
(Mid-Range: About 160 A)
Adjust Remote V/A Control
(Stick Welding Only)
259 872 / 248 009−A / S-0769 / S-0774
OM-279836 Page 39
Complete Parts List available at www.MillerWelds.com
6-10. Updating Software
Obtain the latest firmware to be loaded
from MillerWelds.com.
Copy the desired firmware to an approved
USB flash drive (see Section 9-1).
With the machine turned off, insert the
flash drive into the USB receptacle on the
front of the machine. Turn the Engine Control switch to the Run or Auto-Speed position.
Do not start the engine.
When the machine has powered up, if valid
files exist on the flash drive, the user is
prompted to confirm the start of the download. The Voltmeter/Ammeter display
reads: ALL? NO.
OM-279836 Page 40
Confirm by rotating the Adjust Control/Select button clockwise to select YES. Then
press the Select button.
load by rotating the Adjust Control/Select
button clockwise to select YES. Then
press the Select button.
After the update has started, do not
During the final download, the left meter
display indicates AL C or AL W. The right
meter display indicates the percentage of
the download completed with a number
from 0 to 100.
power down or remove the flash drive
until the update is complete.
During the download, the left meter display
indicates the active download with ALLC
or ALLW. The right meter display indicates
the percentage of the download completed
with a number from 0 to 100.
The Voltmeter/Ammeter display reads: AL
? NO. Confirm the start of the next down-
When the update has completed successfully, the machine restarts.
Failures are indicated on the meter display.
Correction of failed updates depends on
what type of failure occurred.
Complete Parts List available at www.MillerWelds.com
6-11. Summary File
1
1
Summary File
Each time a USB stick is inserted
in the USB receptacle, a summary file is saved to the USB stick as
SummaryFile.txt.
“USB ACC” will display as the file
is written. File is complete when
display no longer shows “USB
ACC.”
The summary file provides diagnostic and weld information.
OM-279836 Page 41
Complete Parts List available at www.MillerWelds.com
6-12. Fuel/Hour Gauge Descriptions
OM-279836 Page 42
Complete Parts List available at www.MillerWelds.com
6-13. Associating ArcReach Devices (ArcReach Models Only)
!
Stop engine.
NOTICE − Do not exceed machine duty cycle.
Associating ArcReach Device To Engine Driven Welder/Generator
Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection
diagrams.
The welder/generator has the ability to associate automatically with an ArcReach device at power up. The Process/Contactor switch must
be set to an Output ON mode to associate with an ArcReach device.
See the ArcReach device Owner’s Manual to associate the device to the welder/generator.
When the association process is complete, the In Use light will be illuminated. Depending on the capabilities of the ArcReach device, the
Process/Contactor switch, Adjust Control/Select button, and Arc Control adjustment may be overridden.
The following ArcReach accessories are compatible with this welder/generator:
ArcReach Stick/TIG Remote
ArcReach SuitCase Feeders
ArcReach Smart Feeder
For Stick Or TIG Welding
For MIG Or FCAW Welding
For Advanced Wire Processes
When welder/generator is associated
with Stick/TIG Remote:
SMAW processes: Amperage,
Electrode Type, and Arc Control
settings are adjusted on the remote.
GTAW and CAC-A processes:
Amperage settings are adjusted on the
remote.
When welder/generator is associated
with Suitcase X-TREME ArcReach
feeder, voltage and wire feed settings
are adjusted on the feeder.
When welder/generator is associated
with Smart Feeder, all controls switch
to the feeder, and the display reads
SMRT ACC.
When using an ArcReach device,
engine
speed
weld/power speed.
is
always
274460-A / 266206-D
OM-279836 Page 43
Complete Parts List available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Supplementary Protectors
1
5
4
3
2
Ref. 248 009
!
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
Unplug power cord before attempting to service accessories or tools.
Generator power decreases as weld
1
current increases.
120/240 V 50 A AC Receptacle RC1
2
120 V 20 A AC Receptacles RC2
and RC3 (GFCI Receptacles Shown)
!
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
OM-279836 Page 44
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is
12.0 kVA/kW.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.
3
Supplementary Protector CB1
CB1 protects standard receptacles RC1,
RC2, and RC3 from overload (for Excel
power information, see Section 7-3). If CB1
opens, the receptacles do not work. Place
switch in On position to reset.
4
Supplementary Protector CB2
CB2 protects RC2 from overload. If CB2
opens, RC2 does not work.
5
Supplementary Protector CB3
CB3 protects RC3 from overload. If CB3
opens, RC3 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 12.0 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 30 A is available
at the 120/240V receptacle:
2 x (120 V x 20 A) + (240 V x 30 A) = 12.0
kVA/kW
Complete Parts List available at www.MillerWelds.com
7-2. GFCI Receptacle Information, Resetting, And Testing
Alternate
location for red
and green indicator LEDs.
1
2
5
4
3
Orientation of receptacle may be different in other applications.
RotGFCI1 2018-01
!
!
1
2
3
4
5
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
Unplug power cord before attempting to service accessories or tools.
120 V 20 A AC GFCI Receptacle
GFCI Receptacle Test Button
GFCI Receptacle Reset Button
Red GFCI Indicator Light (LED)
Green GFCI Indicator Light (LED)
Red and Green indicator lights may be
combined in a single LED.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place ignition switch in RUN
position, and press GFCI Reset button. Reconnect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Resetting/Testing GFCI Receptacle
Testing GFCI Receptacles
!
Test GFCI monthly.
!
Start engine and press the GFCI Test button. The GFCI Reset button should pop out.
If Red LED blinks, stop using GFCI
receptacle and have it replaced by a
Factory Authorized Service Agent.
Press the GFCI Reset button.
!
Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
OM-279836 Page 45
Complete Parts List available at www.MillerWelds.com
7-3. Optional Excel Power
Excel power option provides generator power at idle speed and while
welding. This allows most job site
tools to operate properly at engine
idle speed.
!
Use GFCI protection when
operating auxiliary equipment. If unit does not have
GFCI receptacles, use GFCIprotected extension cord. Do
not use GFCI receptacles to
power life support equipment.
1
120 V 20 A AC Excel Power
Receptacle
1
This receptacle supplies 2.4 kVA/
kW of pure 120 V, 60 Hz sine wave
power at ALL engine speeds.
Circuit protection is provided by
CB3 only; CB1 does not provide
protection to Excel power.
Combined output of all receptacles
limited to peak rating of the generator.
60Hz
ALL
Speeds
Excel power
Run Tools at Idle Speed
Ref. 248 009 / 250 717-C
7-4. Simultaneous Weld And Power
Weld Current in Amperes
Total Power in Watts
120 V Full kVA Receptacle
Amperes
240 V Full kVA Receptacle
Amperes
250
2200
18
9
180
3500
29
14
125
5200
43
21
90
8000
66
33
0
12,000 (Peak)
88
44
OM-279836 Page 46
Complete Parts List available at www.MillerWelds.com
7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
Current Available in Amperes
240 V
Receptacle*
Each 120 V Duplex
Receptacle
42
37
32
27
22
0
5
10
15
20
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.
V x A = Watts
*One 240 V load or two 120 V loads.
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
1
3
Tools Needed:
4
120V
5
120V
240V
6
2
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-279836 Page 47
Complete Parts List available at www.MillerWelds.com
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1.
Maintenance Label
OM-279836 Page 48
Complete Parts List available at www.MillerWelds.com
8-2. Routine Maintenance
!
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
Section 5-5
Coolant Level
Fuel Level
Oil Level
Oil, Fuel Spills
Every
200
Hours
Fuel Connections
Oil
Oil Filter
Air Cleaner
Section 8-3,
8-4, Engine
Manual
Battery Terminals
Unreadable Labels
Every
400
Hours
Weld Terminals
5/16 in.
(8 mm)
Fuel Filters
Belt Tension
Weld Cables
Every
1000
Hours
Engine
Manual,
Section 8-5
Fan Belt
* To be
Every
done
800
by FacHours
tory
Authorized
Service Valve Clearance*
Agent
Flush Radiator
Every
1000
Hours
Radiator Hoses
Air Cleaner Hoses
Section 8-3
Slip Rings*
Brushes*
Every
2000
Hours
Engine
Manual,
Section 8-3
Fuel Hoses
Coolant & Hoses
OM-279836 Page 49
Complete Parts List available at www.MillerWelds.com
8-3.
Engine Maintenance Activities
5
6
7
8
3
4
3
2
1
!
Stop engine and let cool.
Oil And Fuel
1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter according to engine manual.
NOTICE − Close valve and valve cap before
adding oil and running engine.
Fill crankcase with new oil to full mark on dipstick (see Section 5-5).
3 Fuel Lines
Replace fuel lines if cracked or worn.
4 Inline Fuel Filter
Install new filter as shown.
OM-279836 Page 50
5
Fuel Filter
Replace filter according to engine manual.
Wipe up any spilled fuel.
Start engine, and check for fuel leaks.
!
Stop engine, tighten connections as
necessary, and wipe up fuel.
Coolant
6
Radiator Cap
7
Radiator Drain Cock (Located on bottom of radiator)
Drain engine coolant according to procedure in engine manual.
Add engine coolant as follows:
8
Water Bypass Hose
Remove water bypass hose. Add coolant to
radiator until coolant trickles out of water bypass hose. This ensures all air is purged
from the system.
Reinstall hose and radiator cap. Check coolant level in overflow bottle.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
Complete Parts List available at www.MillerWelds.com
8-4. Replacing Air Cleaner
!
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
1
Air Intake Tube
2
Hose Clamp
3
Air Cleaner
Loosen hose clamp, slide air cleaner towards rear of unit and remove. Slide new
air cleaner onto intake tube and tighten
clamp.
Replace air cleaner every 200 hours or
less if used in severe conditions.
3
1
2
907755
OM-279836 Page 51
Complete Parts List available at www.MillerWelds.com
8-5. Adjusting Engine Speed
Engine speed is controlled by an electronic system that can only be adjusted by an engine Factory Authorized Service Station. Tampering with
the electronic governor may void engine warranty.
8-6. Overload Protection
Tools Needed:
!
Stop engine.
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in.
1
Fuse F5
F5 protects the weld excitation
winding from overload. If F1 opens,
weld output stops or is low.
2
1
5
2
Supplementary Protector CB5
Protects optional Excel power
windings from overload. If this
opens, Excel power is not available
at receptacle RC3.
Place switch in On position to reset.
3
Circuit Breaker CB7
CB7 protects the engine glow plug
circuit. If CB7 opens, the glow plug
will not heat. CB7 automatically resets when the fault is corrected.
4
Supplementary Protector CB8
CB8 protects the engine battery circuit. If CB8 opens, the engine will
not crank. CB8 automatically resets when the fault is corrected.
Replace any open fuses. Close
door and/or reinstall cover before
operating unit.
5
Supplementary Protector CB4
CB4 protects the stator winding
supplying 24 volt AC output to Remote receptacle RC4. If CB4
opens, 24 volt AC output to RC4
stops.
Press button to reset.
3
4
259 872
OM-279836 Page 52
Complete Parts List available at www.MillerWelds.com
8-7. Voltmeter/Ammeter Error Displays
IGBT
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions.
TEMP
Display Example
When an error is displayed, normally weld output has stopped but generator power output may be okay.
To reset error displays, stop unit and then restart. See below to reset CHEK REMT display.
Error Display
Description
CHEK REMT
Indicates a remote device connected to the Remote Receptacle may be faulty. CHEK REMT is also displayed whenever a
remote device has been connected to the Remote Receptacle and then disconnected. Clear fault by stopping and restarting
the unit, or by turning Process/Contactor switch to another position. If problem continues, have Factory Authorized Service
agent check the remote device and main control board PC1.
IGBT 1SHT
Indicates the thermistor in IGBT module 1 has shorted. Have Factory Authorized Service Agent check unit.
IGBT 1OPN
Indicates the thermistor in IGBT module 1 is open. Have Factory Authorized Service Agent check unit.
IGBT 2SHT
Indicates the thermistor in IGBT module 2 has shorted. Have Factory Authorized Service Agent check unit.
IGBT 2OPN
Indicates the thermistor in IGBT module 2 is open. Have Factory Authorized Service Agent check unit.
IGBT TEMP
Indicates an IGBT module has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle.
Keep engine access door closed when running unit to maintain proper cooling airflow past module. Allow unit to cool before
restarting. If problem continues, have Factory Authorized Service Agent check unit.
MAX POWR
Engine power limit exceeded, causing weld output to be temporarily reduced. Error clears after 5 seconds.
S/W ERR
Software version mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service
Agent check unit.
S/W BLD
Software build mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service Agent
check unit.
OM-279836 Page 53
Complete Parts List available at www.MillerWelds.com
8-8. Troubleshooting Tables
A. Welding
Trouble
Low or no weld output; generator power output okay at AC receptacles.
Remedy
Check control settings and all connections.
Check fuse F5 and replace if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and main rectifiers SR1, SR2, and
SR3.
No weld output or generator power output at AC receptacles.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes and slip rings.
Low weld output.
Check control settings.
Service air cleaner (see Section 8-2)
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check control settings.
Erratic weld output.
Check control settings.
Tighten and clean connections to electrode and workpiece.
Use dry, properly stored electrodes for Stick and TIG welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welder/generator.
Have Factory Authorized Service Agent check brushes and slip rings.
B. Generator Power
Trouble
No or low generator power output at
AC receptacles; weld output okay.
Remedy
Reset supplementary protectors (see Section 7-1).
Press GFCI receptacle Reset button (see Section 7-2).
Check engine ignition wiring connections.
Have Factory Authorized Service Agent check brushes and slip rings.
No generator power or weld output.
Be sure all equipment is disconnected from receptacles when starting unit.
Check engine ignition wiring connections.
Have Factory Authorized Service Agent check brushes and slip rings.
Erratic power output at AC receptacles.
Check fuel level.
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes and slip rings.
C. Engine
Maintenance Display
Action
noFUEL
Place Engine Control switch in the Off position, refuel, and start engine.
HI H2O
Coolant temperature is too high. Allow engine to cool and check coolant level (see Section 8-3).
LO OIL
Oil pressure is too low. Allow engine to cool and check oil level (see Section 8-3).
OM-279836 Page 54
Complete Parts List available at www.MillerWelds.com
Remedy
Trouble
Engine does not crank.
Supplementary protector CB8 may be open (see Section 8-6). Wait and retry.
Check battery voltage.
Check battery connections; clean and tighten if necessary.
Check Engine Control switch and engine wiring harness connections.
Have Factory Authorized Service Agent check circuit breaker CB8.
Engine cranks but does not start.
Check fuel level and front panel fault indicators (see Section 6-1).
Glow plug circuit breaker CB7 may be open (see Section 8-6). Wait and retry.
Service inline fuel strainer and fuel filter (see Section 8-2).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check Engine Control Unit (ECU) fault codes.
Have Factory Authorized Service Agent check glow plug switch S2, glow plug, and control relay CR1.
Engine starts but stops when Engine
Control switch S1 returns to Auto-Speed position.
Check oil level (see Section 5-6) and front panel fault indicators (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check front panel fault
indicators (see Section 6-1). Engine will not start if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S3 and engine temperature switch S4.
Engine stopped during normal
operation.
Check fuel level and front panel fault indicators (see Section 6-1).
Check oil level (see Section 5-6) and front panel fault indicators (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check front panel fault
indicators (see Section 6-1). Engine stops if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S3 and engine temperature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check alternator voltage according to engine manual.
Engine does not return to idle speed
when load is removed with Engine
Control switch in Auto-Speed position.
Remove all weld and generator power loads.
Have engine Factory Authorized Service Agent check engine and wiring.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Auto-Speed position.
Have engine Factory Authorized Service Agent check engine and wiring.
Engine exhaust smoke black when unit
is under load.
Replace air cleaner.
Replace fuel filter.
OM-279836 Page 55
Complete Parts List available at www.MillerWelds.com
SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
....................
....................
....................
....................
....................
....................
....................
. . . . . . . . GLOW PLUG .
. . . . . . . . . . . F5 . . . . .
....................
....................
....................
....................
....................
....................
....................
OM-279836 Page 56
276418
259935
258349
213858
259934
187443
259949
187820
012655
259974
243344
243345
280496
280495
243341
259982
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
USB Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Kit, Kubota (Includes air cleaner element, fuel, oil filters) . . . . . . . . .
Air Cleaner, Intake Dry Straight Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Fuel (Kubota) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Cer 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Pressure Oil 7psi Nc Cont Screw Term . . . . . . . . . . . . . . . . . . . . . .
Sensor, Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor, Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator, Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Temp 115 Deg C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter, Engine Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Complete Parts List available at www.MillerWelds.com
Notes
OM-279836 Page 57
SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For Welder/Generator
OM-279836 Page 58
277099-B
OM-279836 Page 59
SECTION 11 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1
2
1
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
!
2
Do not use 2-prong plug unless equipment is double
insulated.
3
OR
gen_pwr 2017−01 − ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
OM-279836 Page 60
3
Metal Vehicle Frame
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
!
Bed liners, shipping skids, and
some running gear insulate the
welder/generator from the vehicle
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
11-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
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
11-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive
load
and
requires
approximately six times more power
while starting the motor than when
running (see Section 11-8).
VOLTS 115
AMPS 4.5
Hz
50/60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its
running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-279836 Page 61
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10,550
15,900
23,300
8100
23,300
35,000
46,700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10,700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
Farm Duty Motors Std. (e.g. Conveyors, Feed
Augers, Air Compressors)
Farm Duty Motors High Torque
(e.g. Barn Cleaners, Silo Unloaders, Silo Hoists,
Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-279836 Page 62
Rating
Starting Watts
Running Watts
2 HP
1/3 HP
1000
1650
3400
4400
2900
10,500
1720
1000
650
1000
1400
1100
2800
720
1/2 HP
2575
975
3/4 HP
4500
1400
1/4 HP
1/2 HP
3/4 HP
1 HP
6100
1600
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
8200
10,550
15,900
23,300
8100
2200
2850
3900
6800
2000
6000
5 HP
23,300
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
1/2 HP
500 PSI
550 PSI
700 PSI
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
950
1400
1600
800
750
1000
800
1050
1/3 HP
1/2 HP
1/3 HP
1/2 HP
11-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in.
3/8 in.
1/2 in.
6-1/2 in.
7-1/4 in.
8-1/4 in.
9 in.
10 in.
14 in.
6 in.
8 in.
10 in.
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in.
2 HP, 14 in.
Standard 9 in.
Heavy Duty 12 in.
1/3 HP
18 in.
HID
Metal Halide
Mercury
Sodium
Vapor
400 GPH
900 GPH
3/4 HP, 16 in.
1 HP, 20 in.
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10,500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-279836 Page 63
11-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welder/generator amperage output
must be at least twice the motor’s
running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-279836 Page 64
11-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s
Manual and national, state,
and local codes.
Customer-supplied equipment
4
3
!
Welding
Generator
Output
is required if generator will supply standby power during
emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
5
Essential
Loads
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welder/Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).
OM-279836 Page 65
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4 (25)
6 (16)
8 (10)
10 (6)
12 (4)
14 (2.5)
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4 (25)
8 (10)
10 (6)
12 (4)
14 (2.5)
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-279836 Page 66
6 (16)
Effective January 1, 2018
(Equipment with a serial number preface of MJ 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. LLC, Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of 6. 90 Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
* Canvas Covers
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Induction Heating Coils and Blankets, Cables, and
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
Non-Electronic Controls
FITNESS.
* M-Guns
Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
* Remote Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Auto-Darkening Weld Masks (No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* 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
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* 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 COMMERCIAL AND
INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at Miller’s option,
either: (1) repair; or (2) replacement; or, if approved in writing by
Miller, (3) the pre-approved 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 use).
Products may not be returned without Miller’s written approval.
Return shipment shall be at customer’s risk and expense.
The above remedies are F.O.B. Appleton, WI, or Miller’s authorized
service facility. Transportation and freight are the customer’s
responsibility. TO THE EXTENT PERMITTED BY LAW, THE
REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO
EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL
THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.
Some US states do not allow limiting the duration of an implied
warranty or the exclusion of certain damages, so the above
limitations may not apply to you. This warranty provides specific
legal rights, and other rights may be available depending on your
state. In Canada, some provinces provide additional warranties or
remedies, and to the extent the law prohibits their waiver, the
limitations set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary by province.
miller_warr 2018-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2018 Miller Electric Mfg. LLC
2018−01
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