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OM-294672B
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
2023-10
Engine Driven Welder/Generator
Big Blue
®
450 Duo
CST
For product information,
Owner’s Manual translations, and more, visit
www.MillerWelds.com
OWNER’S MANUAL
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With
Miller, you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a
Troubleshooting section that will help you figure out what the problem is, and our extensive service network is there to help fix the problem.
Warranty and maintenance information for your particular model are also provided.
Miller 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.
Miller is backed by the most hassle-free warranty in the business.
Miller is the first welding equipment manufacturer in the
U. S. A. to be registered to the
ISO 9001 Quality System
Standard.
Mil_Thank1 2019 01
TABLE OF CONTENTS
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 1 – SAFETY PRECAUTIONS – READ BEFORE USING
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.
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 Principal Safety Standards. 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 the ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on.
The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
� Do not touch live electrical parts.
� Wear dry, hole-free insulating gloves and body protection.
� Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.
� Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.
� Use AC output ONLY if required for the welding process.
� If AC output is required, use remote output control if present on unit.
� Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
� Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed.
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 these hazards.
� 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.
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-294672 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 GASES can be hazardous.
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 leather or flame-resistant clothing (FRC). 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.
OM-294672 Page 2
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.
� 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 (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 leather or flame-resistant clothing (FRC). 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.
1-3.
Engine Hazards
� 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.
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.
ENGINE HEAT can cause fire.
� 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.
� Do not locate unit on, over, or near combustible surfaces or flammables.
� Keep exhaust and exhaust pipes way from flammables.
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 injure.
� 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.
OM-294672 Page 3
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.
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 Hazards 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.
OM-294672 Page 4
� Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94-110) when manually lifting heavy parts or equipment.
OVERHEATING can damage motors.
� Turn off or unplug equipment before starting or stopping engine.
� Do not let low voltage and frequency caused by low engine speed damage electric motors.
� Use only equipment suitable for operation on 60 or 50/60 Hz power.
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.
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.
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.
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.
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.
RECYCLE.
� Recycle or dispose of used liquids in an environmentally safe way. This is especially true for engine fluids such as drain oil and used coolant; this is also important for coolant from torch/gun cooling systems.
� Contact your local recycling office or your local distributor for information about how to dispose of parts and equipment in an environmentally safe way.
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.
OM-294672 Page 5
� 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.
as robots.
ARC WELDING can cause interference.
� Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such
1-6.
California Proposition 65 Warnings
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
.
� 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.
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.
For Diesel Engines:
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, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org
.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org
.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org
.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1 from Compressed Gas Association. Website: www.cganet.com
.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org
.
Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian
Standards Association. Website: www.csagroup.org
.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org
.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
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. Website: www.osha.gov
.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.
Website: www.osha.gov
.
Portable Generator Hazards Safety Alert from U.S. Consumer Product Safety Commission (CPSC). Website: www.cpsc.gov
.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH .
For Standards regulating hydraulic systems, contact the National Fluid Power Association. Website: www.nfpa.com
.
Battery Service Manual from the Battery Council International. Website: www.batterycouncil.org
.
ROM 2022–01
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.
OM-294672 Page 6
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
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.
Symboles utilisés
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.
2-2.
Dangers relatifs au soudage à l’arc
Ce groupe de symboles veut dire Avertissement! Attention! DAN-
GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE-
CES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout danger.
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 UNIQUE-
MENT si le procédé de soudage le demande.
� Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
� Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder DC semi-automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
� Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de transfert et une procédure de mise à la terre adéquats ne soient mis en place.
� Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
� Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
� Toujours vérifier la terre du cordon d’alimentation - Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé
à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
� En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
� Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez-les contre les étincelles et les pièces métalliques chaudes.
� Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -, le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraîner la mort.
� Mettre l’appareil hors tension quand on ne l’utilise pas.
� Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés.
� Ne pas enrouler les câbles autour du corps.
� Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct - ne pas utiliser le connecteur de pièce ou le câble de retour.
� Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.
� Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.
� N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp 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.
� Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.
OM-294672 Page 7
� Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
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.
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.
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.
OM-294672 Page 8
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 pendant le soudage (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 une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans huile, comme 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 couper ou souder des jantes ou des roues. Les pneus peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les normes de sécurité.
� 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 (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 porte-
électrode ou couper le fil à la pointe de contact.
� Porter une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans huile, comme 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 endommager l’ouïe.
Le bruit des processus et des équipements peut affecter l’ouïe.
� Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.
Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.
� Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
� Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
� Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
� Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
� Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
� Ne jamais placer une torche de soudage sur une bouteille à gaz.
� Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
� Ne jamais souder une bouteille pressurisée - risque d’explosion.
� Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.
� Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière lerégulateur lors de l’ouverture de la vanne.
� Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
� 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. LA CHALEUR DU
MOTEUR peut provoquer un incendie.
� 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.
� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables.
� Tenir à distance les produits inflammables de l’échappement.
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 deprotection.
� Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-294672 Page 9
� 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 delaborne.
� Ne pas approcher les mains, cheveux, vêtements lâches etoutils 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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent provoquer des brûlures.
� Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler.
� Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).
� Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
� Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur.
� Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon.
L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
� Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisible et inodore.
� JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
� Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les
YEUX ET SUR LA PEAU.
� Ne pas renverser la batterie.
� Remplacer une batterie endommagée.
� Rincer immédiatement les yeux et la peau à l’eau.
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.
2-4.
Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort.
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.
� Une installation ou une utilisation incorrecte de cet appareil pourrait conduire à des dégâts matériels
� Ne pas dépasser le débit nominal ou la capacité du compresseur ou de tout équipement du circuit d’air comprimé. Concevoir le circuit d’air comprimé de telle sorte que la défaillance d’un composant ne risque pas de provoquer un accident matériel ou corporel.
� Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance.
� Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil fonctionne. Seul un personnel qualifié est autorisé, et appliquant les consignes du fabricant.
� Ne pas modifier ou altérer le compresseur ou les équipements fournis par le fabricant. Ne pas débrancher, désactiver ou neutraliser les équipements de sécurité du circuit d’air comprimé.
� Utiliser uniquement des composants et accessoires homologués par le fabricant.
� Se tenir à l’écart de tout point présentant un danger de pincement ou d’écrasement créé par l’équipement raccordé au circuit d’air comprimé.
OM-294672 Page 10
� Ne pas intervenir sous ou autour d’un équipement qui n’est soutenu que par la pression pneumatique. Soutenir l’équipement de fa-
çon appropriée par un moyen mécanique.
MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion.
� Ne pas découper ou gouger à proximité de produits inflammables.
� Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort.
� Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller etétiqueter l’appareil, détendre la pression ets’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 lescomposants du circuit d’air comprimé, lesbranchements 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 unéquipement 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 undétecteur à ultrasons, jamais les mains nues. En cas dedétection de fuite, ne pas utiliser l’équipement.
� Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand l’entretien est terminé et avant de mettre enmarche 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 lamort.
� 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
ETDES 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 ducompresseur.
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 des pièces de remplacement provenant du fabricant.
� 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.
Symboles de 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 dimensionné et protégé avant de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
� Utiliser seulement l’anneau de levage pour soulever l’appareil et des accessoires correctement installés, non pas les bouteilles de gaz. Ne pas dépasser les capacités maximales de l’anneau de levage (voir
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 № 94–110) lors du levage manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
� Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
� Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
� Utiliser uniquement des équipements adéquats pour un fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.
� Porter un écran facial pour protéger le visage et les yeux.
� Affûter l'électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du visage, des mains et du corps.
� Les étincelles risquent de causer un incendie - éloigner toute substance inflammable.
Les PIÈCES MOBILES peuvent causer des blessures.
� Ne pas s’approcher des organes mobiles.
� Ne pas s’approcher des points de coincement tels que des rouleaux de commande.
OM-294672 Page 11
LA SORTIE DE RECHARGE et
L’EXPLOSION DE LA BATTERIE peuvent provoquer des blessures.
La recharge de batterie n’existe pas sur tous les modèles.
� Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
� Arrêter le moteur avant de débrancher ou de brancher des câbles de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien.
� Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie.
� Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.
� Observer la polarité correcte (+ et -) sur les batteries.
� Débrancher le câble négatif (-) en premier lieu. Le rebrancher en dernier lieu.
� Les sources d’étincelles, flammes nues, cigarettes et autres sources d’inflammation doivent être maintenues à l’écart des batteries.
Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge.
� Suivre les instructions du fabricant de la batterie lors d’opérations sur une batterie ou à proximité de celle-ci. Voir le manuel de service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
� Les opérations de charge de batterie ne doivent être effectuées que par des personnes qualifiées.
� Pour enlever la batterie d’un véhicule pour la recharge, débrancher tout d’abord le câble négatif (-) et le rebrancher en dernier lieu. Pour éviter un arc, s’assurer que tous les accessoires sont débranchés.
� Ne charger que des batteries plomb-acide. Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit électrique basse tension ou pour charger des batteries sèches.
� Ne pas charger une batterie gelée.
� Ne pas utiliser de câbles de charge endommagés.
� Ne pas charger des batteries dans un espace fermé ou en l’absence d’une ventilation.
� Ne pas charger une batterie dont les bornes sont desserrées ou présentant une détérioration comme par exemple un boîtier ou un couvercle fissuré.
� Avant de charger une batterie, sélectionner la tension de charge correspondant à la tension de la batterie.
� Régler les commandes de charge de batterie sur la position d’arrêt avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.
� Ranger les câbles de charge à distance du capot, des portes et des pièces mobiles du véhicule.
LES LIQUIDES PRESSURISÉS peuvent blesser ou tuer.
� Les composants du système d’alimentation peuvent contenir du carburant sous pression élevée.
� Avant d’intervenir sur le système d’alimentation de carburant, arrêter le moteur pour dépressuriser le système.
� En cas d’injection de tout liquide sous la peau ou dans le corps, solliciter une aide médicale sur le champ.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
� Ne pas appuyer sur la gachette 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.
OM-294672 Page 12
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
� Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
� Réduire le courant ou le cycle opératoire avant de recommancer le soudage.
� Ne pas obstruer les passages d’air du poste.
LES CHARGES
ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
� Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
� Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
UNE REMORQUE QUI BASCULE peut provoquer des blessures.
� Utiliser les supports de la remorque ou des blocs pour soutenir le poids.
� Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
RECYCLER.
� Recycler ou éliminer les liquides usagés d’une manière respectueuse de l’environnement. Cela est particulièrement vrai pour les fluides du moteur tels que l’huile de vidange et le liquide de refroidissement usagés ; ceci est également important pour le liquide de refroidissement provenant des systèmes de refroidissement de la torche/du pistolet.
� Contactez votre bureau de recyclage local ou votre distributeur local pour obtenir des informations sur la manière de mettre au rebut les pièces et l’équipement d’une manière respectueuse de l’environnement.
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 des pièces de remplacement provenant du fabricant.
� 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, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org
.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org
.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org
.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1 from Compressed Gas Association. Website: www.cganet.com
.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org
.
Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian
Standards Association. Website: www.csagroup.org
.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org
.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
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. Website: www.osha.gov
.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.
Website: www.osha.gov
.
Portable Generator Hazards Safety Alert from U.S. Consumer Product Safety Commission (CPSC). Website: www.cpsc.gov
.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH .
For Standards regulating hydraulic systems, contact the National Fluid Power Association. Website: www.nfpa.com
.
Battery Service Manual from the Battery Council International. Website: www.batterycouncil.org
.
ROM_fre 2022–01
OM-294672 Page 13
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-294672 Page 14
1-1.
Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
1-1.
Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Some symbols are found only on CE products.
Safe1 2012 05
Do not discard product (where applicable) with general waste.
Warning! Watch Out! There are possible hazards as shown by the symbols.
facility.
Contact your local recycling office or your local distributor for further information.
1-1.
Additional Safety Symbols And Definitions
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
Some symbols are found only on CE products.
Some symbols are found only on CE products.
Contact your local recycling office or your local distributor for further information.
Safe37 2017 04
�
Complete Parts List is available at www.MillerWelds.com
Safe2 2017 04
SECTION 3 – DEFINITIONS
Warning! Watch Out! There are possible hazards as shown by the symbols.
3-1.
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Additional Safety Symbol Definitions
Safe1 2012 05
Safe1 2012 05
Safe2 2017 04 �
Some symbols are found only on CE products.
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
facility.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Contact your local recycling office or your local distributor for further information.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017 04
Safe37 2017 04
Safe37 2017 04
Wear dry insulating gloves. Do not touch electrode with bare hand.
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe3 2017 04
Safe4 2017 04
Safe2 2017 04
Safe2 2017 04
Safe4 2017 04
Safe5 2017 04
Protect yourself from electric shock by insulating yourself from work and ground.
Protect yourself from electric shock by insulating yourself from work and ground.
Keep your head out of the fumes.
Use ventilating fan to remove fumes.
Safe3 2017 04
Safe3 2017 04
Safe10 2012 05
Protect yourself from electric shock by insulating yourself from work and ground.
Protect yourself from electric shock by insulating yourself from work and ground.
Keep your head out of the fumes
Use ventilating fan to remove fumes.
Safe4 2017 04
Safe4 2017 04
Safe6 2017 04
Safe7 2017 04
Disconnect input plug or power before working on machine.
Disconnect input plug or power before working on machine.
Keep your head out of the fumes
Use forced ventilation or local exhaust to remove the fumes.
Keep flammables away from welding. Do not weld near flammables.
Safe5 2017 04
Safe5 2017 04
Safe12 2012 05
Keep your head out of the fumes.
Keep your head out of the fumes.
Safe6 2017 04
Safe6 2017 04
Safe13 2012 05
OM-
Keep your head out of the fumes
Keep your head out of the fumes
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe7 2017 04
Safe7 2017 04
Safe12 2012 05
Safe13 2012 05
OM-
Use forced ventilation or local exhaust to remove the fumes.
Use forced ventilation or local exhaust to remove the fumes.
Welding sparks can cause fires. Have a fire extinguisher nearby, and
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe8 2012 05
Safe8 2012 05
Use forced ventilation or local exhaust to remove the fumes.
Use forced ventilation or local exhaust to remove the fumes.
Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Do not weld on drums or any closed containers.
Safe9 2012 05
Safe9 2012 05
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OM-
Do not weld on drums or any closed containers.
Do not cut on drums or any closed containers.
OM-294672 Page 15
Safe16 2017 04
Safe17 2017 04
Do not cut on drums or any closed containers.
Do not grip material near cutting path.
Safe17 2017 04
Safe18 2017 10
Safe16 2017 04
Safe17 2017 04
Do not cut on drums or any closed containers.
Do not grip material near cutting path.
Do not remove or paint over (cover) the label.
Do not remove or paint over (cover) the label.
Safe19 2012 05
Safe20 2017 04
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Safe20 2017 04
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Turn off power before disassembling torch.
Do not remove or paint over (cover) the label.
Do not remove or paint over (cover) the label.
OM-
Safe20 2017 04
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Use ventilating fan to remove fumes.
Safe10 2012 05
Use ventilating fan to remove fumes.
Safe11 2012 05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012 05
Keep flammables away from cutting. Do not cut near flammables.
Safe13 2012 05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012 05
Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe15 2012 05
Do not weld on drums or any closed containers.
Safe16 2017 04
Do not cut on drums or any closed containers.
Safe17 2017 04
Do not grip material near cutting path.
Safe18 2017 10
Turn off power before disassembling torch.
�
Complete Parts List is available at www.MillerWelds.com
Safe19 2012 05
Safe20 2017 04
OM-
Writer: If necessary, replace the word “handle” with “lift eye’.
Do not use one handle to lift or support unit.
Do not work on unit if engine is running. Stop engine first.
Safe31 2017 04
Drive rolls can injure fingers.
Do not smoke while fueling or if near fuel.
Safe32 2012 05
Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away.
Safe33 2017 04
Stop engine before fueling.
Consult rating label for input power requirements.
Safe34 2012 05
Do not fuel a hot engine.
Do not fuel a hot engine.
Do not fuel a hot engine.
Become trained and read the instructions and labels before working on machine.
OM-294672 Page 16
Safe35 2012 05
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait
Connect Green Or Green/Yellow grounding conductor to ground terminal first.
60 seconds
after power is turned off before working on unit, AND check input capacitor voltage, and be sure it is near 0 before touching any parts.
Keep your head out of the fumes
Wear hat and safety glasses. Use ear protection and button shirt col-
Wear hat and safety glasses. Use ear protection and button shirt off. Do not touch fully charged capacitors. Always wait
5 minutes
after body protection made from leather or flame-resistant clothing (FRC).
body protection.
voltage, and be sure it is near 0 before touching any parts.
=< 60
°
Always lift and support unit using both handles. Keep angle of lifting
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe39 2012 05
Safe44 2012 05
Become trained and read the instructions before working on the machine or cutting.
Safe45 2012 05
Become trained and read the instructions before working on the machine or cutting.
After taking proper precautions as shown, connect power to unit.
Follow instructions to install muffler.
Safe46 2012 05
Every 100 hours, check and clean filter and check condition of hoses.
Safe21 2017 04
Safe21 2017 04
Safe22 2017 04
Safe23 2017 04
Safe24 2017 04
Safe25 2012 05
Safe26 2012 05
Safe27 2012 05
Safe28 2012 05
Safe29 2012 05
Safe47 2012 05 grounding conductor first. Connect line input conductors as shown on inside label. Double-check all connections, jumper link positions, and
Safe54 2017 04 input voltage before applying power.
Safe49 2012 05
After the first 50 hours of operation, change the engine oil and filter.
Plugged filter or hoses can cause overheating to the power source and torch.
Safe55 2012 05
Safe50 2012 05
Every 100 hours, check and clean filter and check condition of hoses.
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Safe51 2012 05
Safe57 2017 04
Use coolant suggested by the manufacturer.
Become trained and read the instructions before working on the machine or welding.
Safe52 2012 05
Safe65 2012 06
°
Falling unit can cause injury. Do not move or operate unit where it could tip.
Induction heating can cause injury or burns from hot items such as rings, watches, or parts.
Safe53 2017 04
Safe74 2012 07
OM-
Safe30 2012 05
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OM-
=< 60
° °
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait
60 seconds
off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, AND check input capacitor voltage, and be sure it is near 0 before touching any parts.
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait
5 minutes
after power is turned off before working on unit, AND check input capacitor voltage, and be sure it is near 0 before touching any parts.
Always lift and support unit using both handles. Keep angle of lifting device less than 60 degrees.
�
Complete Parts List is available at www.MillerWelds.com
machine or welding.
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Wire
<12.4 V
Safe41 2012 05
Safe41 2012 05
Safe47 2012 05
Safe47 2012 05
Move jumper links as shown on inside label to match input voltage at
Move jumper links as shown on inside label to match input voltage at inside label. Double-check all connections, jumper link positions, and inside label. Double-check all connections, jumper link positions, and input voltage before applying power.
Safe49 2012 05
/
+ +
Safe117 2014 06
Plugged filter or hoses can cause overheating to the power source
Plugged filter or hoses can cause overheating to the power source and torch.
Safe50 2012 05 amperes. Do not weld below 200 amperes of output.
Every 100 hours, check and clean filter and check condition of hoses.
machine or heating.
Become trained and read the instructions before working on the
Recycle or dispose of used coolant in an environmentally safe way.
Safe51 2012 05
Safe85 2012 06
After the first 50 hours of operation, change the engine oil and filter.
Safe119 2015 05
Use coolant suggested by the manufacturer.
Use coolant suggested by the manufacturer.
Connect input conductors (L1, L2 And L3) to line terminals.
Safe52 2012 05
Safe86 2012 06
Hot Parts can burn. Do not touch hot parts bare-handed. Allow cooling period before handling parts or equip-
°
°
ment.
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
dows are open.
Safe120 2015 11
Never use generator inside a home or garage, even if doors and win-
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Connect Green Or Green/Yellow grounding conductor to ground terminal first.
Connect input conductors (U/L1, V/L2, W/L3) to line terminals.
Safe87 2012 07
Safe57 2017 04
OM-
OM-
Safe121 2016 04
Only use generator outside and far away from windows, doors, and vents.
Use a proper cart to move unit.
Safe65 2012 06
Safe65 2012 06
Safe122 2016 04
Environmental Protection Use Period (China)
Safe123 2016 06
Feed wire between guide pins into drive rolls.
Safe124 2017 02
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
OM-294672 Page 17
Do not spray water on CST units.
Door must be fully open during operation.
OM-
Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away.
Become trained and read the instructions before working on the machine or heating.
Connect green or green/yellow grounding conductor to ground terminal.
Connect input conductors (L1, L2 And L3) to line terminals.
Safe86 2012 06
Safe86 2012 06
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
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2017 04
Hot muffler and exhaust pipe can cause severe burns.
�
Complete Parts List is available at www.MillerWelds.com
Welding, cutting, drilling, or grinding on base can cause fire or
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
Safe90 2017 04
Safe91 2017 04
Do not spray water on CST units.
Safe92 2017 04
Safe93 2012 08
3-2.
Miscellaneous Symbols And Definitions
Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away.
Amperage
Maximum Power
Consumption
TIG (GTAW)
Welding
Safe95 2012 05
Voltage Welding Arc
Hertz
Seconds
Duty Cycle
Current
Suitable For Welding In An Environment With
Increased Risk Of
Electric Shock
Engine-Driven,
Three-Phase Alternator With Rectifier
Three Phase
Engine Stop
Engine Start
(Engine RPM)
Run (Fast)
OM-
OM-
Rated No Load Voltage (OCV)
Conventional Load
Voltage
Rated Welding
Current
Rated Load Speed
Rated No Load
Speed
Rated Idle Speed
Single Phase
Direct Current (DC)
Alternating Current
(AC)
Circuit Protection
Protective Earth
(Ground)
Stick (SMAW)
Welding
Idle (Slow)
Starting Aid
(Preheat)
Output
On
Off
Remote
OM-294672 Page 18
34
Complete Parts List is available at www.MillerWelds.com
Positive
�
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Hour Meter
Hours Negative
Engine
Engine
Check Air Cleaner
Battery (Engine)
Temperature
Manual (13 mm)
Engine Coolant
Fuel
Certified/Trained
Mechanic
Check Spark
Arrestor
Check Engine Belt
Tension
Call For
Maintenance
Engine Oil
Air Filter
FUEL
SLUDGE
Check Injectors/
Pump
OM-278215 Page 33
OM-294672 Page 19
1
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SECTION 4 – SPECIFICATIONS
4-1.
Serial Number And Rating Label Locations
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.
Software Licensing Agreement
The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at https://www.millerwelds.com/eula and are incorporated by reference herein.
4-3.
Information About Default Weld Parameters And Settings
NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.
4-4.
Weld, Power, And Engine Specifications
�
This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C).
Welding Output
Rated Output Tier 4 Final Engine
(Domestic Models)
Welding Amperage
Range
Maximum Open-Circuit
Voltage
Stick (SMAW)
TIG (GTAW)
Individual CST:
280 A @ 31.2 VDC, 35 % Duty Cycle
200 A @ 28 VDC, 100 % Duty Cycle
Combined Rating:
350A @ 27 VDC, 100% Duty Cycle
5-280 A 103 VDC
Auxiliary Power Rating Sound Level Engine Fuel Capacity
Single-Phase, 10.5 kVA/kW Peak
8.9 kVA/kW, Continuous
120/240 V AC, 60 Hz
71 dB (96 Lwa) at 23 ft (7 m),
Four-Cylinder Diesel Engine 24.7
10.0 gal (37.8 L)
Full Load (T4F)
HP Domestic Models (T4F)
2-1.
Dimensions, Weights, And Operating Angles
4-5.
Dimensions, Weights, And Operating Angles
Height
Width
Depth
A
B
C
D
Dimensions
32 in. (813 mm)
35.75 in. (908 mm)(to top of lift eye)
26.25 in. (667 mm)
(mtg. brackets turned in)
28.75 in. (730 mm)
(mtg. brackets turned out)
56 in. (1422 mm)
56 in. (1422 mm)
54 in. (1372 mm)
52 in. (1321 mm)
2 in. (51 mm)
E
F
G
H
26 in. (660 mm)
7/8 in. (22 mm)
27.75 in. (705 mm)
9/16 in. (14 mm) Dia.
4 Holes
Weight
No Fuel: 1064 lb (483 kg)
With Fuel: 1159 lb (526 kg)
Lifting Eye Weight Rating:
2000 lb (907 kg) Maximum
A
B C
D
G
H
Front Panel End
E
F
°
°
Do not exceed tilt angles or engine could be damaged or unit could tip.
Do not move or operate unit where it could tip.
20
°
20
°
907866
°
°
�
For information on specifications and performance data pertaining to standard CST units operating individually, see Miller Owner’s Manual
OM-217655. Use this Owner’s Manual in conjunction with OM-217655 for operation, maintenance, and troubleshooting.
OM-294672 Page 20
30
°
30
°
400
300
200
0 10 20 30 40 50
% DUTY CYCLE
60 70 80 90 100
266504-A
OM-278215 Page 31
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Complete Parts List is available at www.MillerWelds.com
4-6.
Environmental Specifications
A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.
B. Temperature Specifications
Operating Temperature Range *
–40 to 104°F (–40 to 40°C)
*Output is derated at temperatures above 104°F (40°C).
4-7.
Duty Cycle And Overheating
Storage/Transportation Temperature Range
–40 to 131°F (–40 to 55°C)
1 100% Duty Cycle
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
�
Each unit is rated for welding at 200 amperes continuously.
Combined rating is 400 amperes at
100% duty cycle.
NOTICE – Exceeding duty cycle can damage unit and void warranty.
1
277791-A
OM-294672 Page 21
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4-8.
Volt-Ampere Curves: Stick
XX10 Stick Mode
The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.
XX18 Stick Mode
OM-294672 Page 22
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4-9.
Volt-Ampere Curves: TIG
The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.
4-10. AC Generator Power Curve
The AC power curve shows the generator power in amperes.
4-11. Fuel Consumption
Single Operator
Duo Operator
295650A
The curve shows typical fuel use under weld or power loads.
OM-294672 Page 23
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SECTION 5 – INSTALLATION
5-1.
Installing Welder/Generator
Movement And Airflow Clearance
18 in.
18 in.
(460 mm)
18 in.
18 in.
(460 mm)
18 in.
(460 mm)
18 in.
(460 mm)
18 in.
(460 mm)
Location/Mounting
2
2 3
4 allen_wrench pliers solderiron allen_set needlenose stripcrimp
NGO’s tools/ 1
1 knife flathead steelbrush philips head
9/16 in.
�
Go to MillerWelds. com for more information on truck installations.
Movement
Do not move or operate unit where it could tip.
�
See Specifications for lifting eye rating.
Airflow Clearance nutdriver
Do not install unit where air flow is restricted or engine may overheat.
chippinghammer
Location/Mounting
Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.
Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
NOTICE – Do not mount unit by supporting the base only at the four mounting brackets.
Use cross-supports to adequately support unit and prevent damage to base.
1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brackets.
3 1/2 in. Bolt And Washer (Minimum - Not
Supplied)
4 3/8-16 x 1 in. Screws (Supplied)
To Bolt Unit In Place:
Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware.
Mount unit to truck or trailer with 1/2 in. (12 mm) or larger hardware (not supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at the four mounting brackets.
heavy-duty workclamp light-duty workclamp
OM-294672 Page 24 wirecutter frontcutter
OM-4413 Page 1 torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun file filterwrench paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench
OM-222 Page 1
1-1.
Installing Exhaust Pipe �
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5-2.
Grounding Generator to Truck or Trailer Frame
1-1.
Grounding Generator To Truck Or Trailer Frame
GND/PE
1 2
3
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 Equipment Grounding Terminal (On
Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire.
�
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
Exhaust1 2018 01 / Ref. 803604
5-3.
Installing Exhaust Pipe
1-2.
Installing Exhaust Pipe
Stop engine and let cool.
�
Point exhaust pipe in desired direction but always away from front panel and direction of travel.
allen_wrench allen_set
NGO’s tools/ flathead philips head wrench
1/2 in.
crescent wrench pliers needlenose knife steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun file filterwrench paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench
OM-222 Page 1
Exhaust Pipe3 2018 01 / Ref. 803582
OM-4428 Page 1
OM-294672 Page 25
OM-236 948 Page 1
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Complete Parts List is available at www.MillerWelds.com
5-4.
Connecting The Battery
allen_wrench pliers allen_set needlenose knife
NGO’s tools/ flathead steelbrush
1/2 in.
philips head �
Shown with door open and rocker panel removed.
NOTICE – Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open-circuit voltage nutdriver chippinghammer
Connect negative (-) cable last.
NOTICE – Wait two minutes after engine shutdown before disconnecting battery or engine controller may be damaged.
Battery is accessed through the side door.
Connect battery, negative cable last. Close side door.
� Do not allow the battery cables to touch opposing terminals. When connecting the battery cables attach the positive
(+) cable to the positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal.
� Never start the engine when the cables are loose or poorly connected to the battery terminals.
� Never disconnect the battery while the engine is running.
� Never use a quick battery charger to start the engine.
� Do not charge battery with Engine Control switch On.
� Always disconnect the negative (-) battery cable before charging battery.
solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp drill
5-5.
Engine General Information
light-duty workclamp
�
Check all engine fluids daily.
wirecutter frontcutter
Engine must be cold and on a level surface.
Automatic Shutdown System
Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high.
greasegun
�
This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level.
filterwrench
Run-In
Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe
during run-in, see Section 11.
NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Light or no load may cause wetstacking or engine damage.
Cold Weather
�
To improve cold weather starting:
Use Preheat switch (see Section 6-1).
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
Use engine block heater if applicable
handream strapwrench airgun qtip (swab) vicegrip hammer awl file paintbrush crimper feelergauge
OM-294672 Page 26 flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench
OM-222 Page 1
�
Complete Parts List is available at www.MillerWelds.com
5-6.
Engine Fuel And Coolant Prestart Information
Fuel
NOTICE – Do not use gasoline. Gasoline will damage engine.
1 Diesel
2 Full
Add fresh diesel fuel before starting (see engine maintenance label for fuel specifications). Stop filling once the level is within 2–
3 inches of the lower neck to allow for fuel expansion.
�
Engine stops if fuel level is low.
Coolant
3 Radiator Coolant Level
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom of filler neck. Capacity is 6 qt (5.7 L).
4
5
6
Coolant Recovery Tank
Hot Full
Cold Full
Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot
Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to -34° F (-37° C). Add antifreeze to mixture if using the unit in temperatures below -34° F (-37° C).
Keep radiator and air intake clean and free of dirt.
NOTICE – Incorrect engine temperature can damage engine. Do not run engine without a properly working thermostat and radiator cap.
OM-294672 Page 27
�
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5-7.
Mitsubishi Engine Oil Prestart Information
Complete Parts List is available at www.MillerWelds.com
Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).
1 Full
1
5-8.
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.
Welding
Amperes
100
150
200
250
300
350
1
400
500
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***
100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m)
350 ft
(105 m)
10 - 60%
Duty Cycle
AWG (mm 2 )
60 - 100%
Duty Cycle
AWG (mm 2 )
10 - 100% Duty Cycle AWG (mm 2 )
4 (20)
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
4 (20)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
3 (30)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
2 (35)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
1 (50)
2/0 (70)
2x3/0 (2x95)
2x3/0 (2x95)
1/0 (60)
3/0 (95)
2x3/0 (2x95)
2x4/0
(2x120)
400 ft
(120 m)
1/0 (60)
3/0 (95)
3/0 (95)
4/0 (120)
4/0 (120)
2x2/0 (2x70)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
2x4/0
(2x120)
2x4/0
(2x120)
2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95)
2x4/0
(2x120)
3x3/0 (3x95) 3x3/0 (3x95)
**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.
( ) = mm 2 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
.
OM-278215 Page 35
OM-294672 Page 28
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5-9.
Weld Output Terminals
Turn off power before connecting to weld output terminals.
Do not use worn, damaged, undersized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (-) Weld Output Terminal
�
All connections are Tweco type.
�
See Sections 5-10 thru 5-11 for stand-
ard connection diagrams.
1 2 1 2
OM-294672 Page 29
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5-10. Making Dual Operator CC Weld Connections With Common Work Cables
1
2
Stop engine.
Failure to properly size and connect weld cables may cause excessive heat and start a fire, or damage your machine.
NOTICE – When making weld connections with a common work cable, connect separate cables of adequate size and equal length to the weld output receptacles.
Where the weld cables are joined, be sure connecting hardware is adequate for expected amperage and that the junction is properly insulated.
NOTICE – When using these connections as a common work terminal, all connections must be of the same polarity.
NOTICE – For common work connection, work cable must be able to carry combined
weld output of both modules (see Section 5-
NOTICE – Do not exceed machine duty cycle.
1 Electrode Holder Cables For DCEP
2 Common Work Cable
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect common work cable to workpiece.
Connect electrode holder cables to Positive
(+) receptacles.
For Stick/TIG Direct Current Electrode Negative (DCEN), reverse connections.
OM-294672 Page 30
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5-11. Paralleling CST Units For SMAW Welding
1 2
Stop engine.
Failure to properly size and connect weld cables may cause excessive heat and start a fire, or damage your machine.
NOTICE – When making weld connections with a common cable, connect separate cables of adequate size and equal length to the weld output receptacles. Where the weld cables are joined, be sure connecting hardware is adequate for expected amperage and that the junction is properly insulated.
NOTICE – When using these connections as a common work terminal, all connections must be of the same polarity.
NOTICE – For common work connection, work cable must be able to carry combined
weld output of both modules (see Section 5-
NOTICE – Do not exceed machine duty cycle
1 Electrode Holder Cable For DCEP
2 Common Work Cable
For Stick welding Direct Current Electrode
Positive (DCEP), connect common work cable to workpiece.
Connect electrode holder cable to Positive
(+) receptacles.
For Stick Direct Current Electrode Negative
(DCEN), reverse connections.
�
Be sure Process Select switches are set the same. Be sure Amp Adjust controls are set the same. See Section
OM-294672 Page 31
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SECTION 6 – OPERATION
6-1.
Front Panel Engine Controls
907866/Ref:293674
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 and stop engine.
To Start:
NOTICE – Do not use ether.
�
If engine does not start, let engine come to a complete stop before attempting restart.
Above 32° F (0° C): turn Engine Control switch to Start. Release Engine Control switch when engine starts.
Below 32° F (0° C): turn engine control switch to Run position. Push Preheat switch up for 30 seconds. Turn Engine Control switch to Start. Release Engine Control switch and Preheat switch when engine starts.
To Stop: turn Engine Control switch to Off position.
Engine Gauges, Meters, And Lights
�
See Section 6-3 for complete fuel/hour
gauge information.
3 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine operating hours, or hours to oil change.
To check fuel level or engine hours when engine is not running, turn Engine Control switch to Run position.
4 Engine Indicator Light
Light goes on and engine stops if engine temperature exceeds 230° F (110° C), engine oil pressure is below 10 psi (69 kPa), or fuel is low.
�
Normal engine temperature is 180 -
203° F (82 - 95° C). Normal oil pressure is 30 - 60 psi (207 - 414 kPa).
NOTICE – Do not run engine until trouble is fixed.
OM-294672 Page 32
�
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6-2.
Operating Optional Engine Block Heater
1 Engine Block Heater Plug
Use heater to maintain a constant engine coolant temperature.
To turn on heater, connect heater plug to 120 volts AC receptacle.
Do not run engine while engine block heater is on.
NOTICE – In extremely cold weather, heater should be connected to power source when engine is warm.
The area near the engine block heater gets hot.
Disconnect plug to turn off heater.
Heater Specifications
Engine
Mitsubishi
Watts
400
Volts ±10%
120
OM-294672 Page 33
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6-3.
Fuel/Hour Gauge Descriptions
OM-294672 Page 34
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6-4.
Front Panel CST Controls
A. Interface Controls
1
2
3
4
5
6
12
285215-A / Ref. m907770
1 Power Switch
2 VRD Indicator Light
3 High Temperature Shutdown Light
4 Output Indicator Light
11 10
5 Amps Display
6 Amperage Adjustment Buttons
7 TIG Process Select
8 Lift-Arc Indicator Light
9 8 7
9 Arc Control Select
10 Arc Control Indicator Light
11 Stick Process Select
12 Electrode Indicator Light
OM-294672 Page 35
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B. Interface Operation Description
Power Switch
VRD Indicator Light
High Temperature
Shutdown Light
Use switch to turn unit and indicator light On/Off.
When the unit is configured for low open circuit voltage, this indicator light will illuminate.
When unit is first energized this indicator light illuminates for approximately 1 second to provide visual confirmation that the light is functioning properly. If unit overheats or is operated at an over duty cycle condition , this light will illu-
minate and output will stop (see Section 4-7).
Output Indicator Light When unit is first energized this indicator light Illuminates for approximately 1 second to provide visual confirmation that the light is functioning properly and then illuminates continuously.
Amps Display
Amperage Adjustment
Buttons
This display illuminates and shows amperage for either TIG or stick welding process. Measured amperage just prior to the end of a welding operation will appear on the display for three seconds after welding operation.
Use these buttons to set the desired amperage setting for either TIG or stick welding process.
TIG Process Select
Lift-Arc
Light
™ Indicator
Press and release this button to activate the TIG welding process. Use the amperage adjustment buttons to set the amperage to the appropriate welding setting.
This light will illuminate when the TIG process is selected.
Arc Control Select
Arc Control Indicator
Light
Press until the desired ARC Control setting indicator light is selected (STIFF or SOFT).
The indicator light for the active ARC Control setting will illuminate when the ARC Control select button is pressed while in the STICK mode.
STICK Process Select Press and release this button to activate the STICK welding process controls and switch between electrode types
(EXX10 or EXX18). Press until the desired electrode type is selected. The electrode indicator light of the desired electrode type will illuminate when selected. Use the amperage adjustment buttons to set the amperage to the appropriate welding setting.
Electrode Indicator
Light
The indicator light for the active STICK electrode type will be illuminated when in the STICK mode.
Table 6–1. Recommended Process Selections vs Electrode Type
Electrode Type Suggested Process Setting
EXXX1
EXXX2
EXXX3
EXXX4
EXXX5
EXXX6
EXXX7
EXXX9
Stainless
EXX10
EXX10
EXX18
EXX18
EXX18
EXX18
EXX18
EXX18
EXX18
OM-294672 Page 36
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SECTION 7 – OPERATING AUXILIARY EQUIPMENT
7-1.
Generator Power Receptacles
1
4
3
2
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment.
Unplug power cord before attempting to service accessories or tools.
1 240 V 50 A AC Receptacle RC11
Supplies 60 Hz single-phase power at weld/ power speed. Maximum continuous output from RC11 is 10 kVA/kW.
2 120 V 20 A AC GFCI Receptacles
GFCI1, GFCI2
GFCI1 and GFCI2 supply 60 Hz singlephase power at weld/power speed.
907866/293674
Maximum output from each receptacle is 2.4
kVA/kW.
Test GFCI monthly. See Section 7-2
for GFCI information and for resetting and testing procedures.
�
If a supplementary protector continues to open, contact Factory Authorized
Service Agent.
3 Supplementary Protectors CB4, CB5
CB4 and CB5 protects GFCI receptacles from overload. If a supplementary protector opens, the receptacle does not work. Press button to reset.
�
Generator power decreases as weld output increases.
Combined output of all receptacles is limited to the 10 kVA/kW (continuous) rating of the generator.
4 Supplementary Protector CB6
EXAMPLE: If 15 A is drawn from each 120 V receptacle , only 26 A is available at the 240
V receptacle:
Supplementary protector CB6 protects receptacles and the generator winding from overload. If CB6 opens, the receptacles do not work. Place CB6 switch in On position to reset circuit breaker.
2 x (120 V x 15 A) + (240 V x 26 A) = 10.0
kVA/kW
OM-294672 Page 37
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Complete Parts List is available at www.MillerWelds.com
7-2.
GFCI Receptacle Information, Resetting, And Testing
1
4
3
5
2
6
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment.
Unplug power cord before attempting to service accessories or tools.
1 120 V 20 A AC GFCI Receptacle
2 GFCI Receptacle Test Button
3 GFCI Receptacle Reset Button
4 Red GFCI Indicator Light (LED)
5 Green GFCI Indicator Light (LED)
6 Alternate Location For Red And Green
Indicator LEDs
�
Red and Green indicator lights may be combined in a single LED.
�
Orientation of receptacle may be different in other applications.
GFCI Receptacles
GFCI receptacles protect the user from electric shock if a ground fault occurs in equipment connected to the receptacle. A ground fault occurs when electrical current takes the shortest path to ground (which could be through a person) rather than follow its intended safe path.
If a ground fault is detected, the GFCI Reset button pops out, and the circuit opens to disconnect power to the faulty equipment. A
GFCI receptacle does not protect against circuit overloads, short circuits, or shocks not related to ground faults. Reset and test
GFCI receptacle according to the following procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting/Testing GFCI Receptacle
Test GFCI monthly.
If Red LED blinks, stop using GFCI receptacle and have a Factory Authorized Service Agent replace it.
Extension cords with bad insulation or of extended length can allow enough leakage current to trip the
GFCI circuit. Reset and test as follows.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords, plugs, etc. connected to the receptacle.
Start engine, place engine control switch in
RUN position, and press GFCI Reset button.
Reconnect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check the equipment and repair or replace if faulty.
Testing GFCI Receptacles
�
Test GFCI receptacles at high engine speed only.
Start engine and place engine control switch in Run position. Press the GFCI Test button.
The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have a Factory Authorized Service Agent replace GFCI if any of the following occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
OM-294672 Page 38
�
Complete Parts List is available at www.MillerWelds.com
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING
8-1.
Maintenance Label
OM-294672 Page 39
�
Complete Parts List is available at www.MillerWelds.com
8-2.
Routine Maintenance
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.
�
Recycle engine fluids.
Every
50
Hours
Every
100
Hours
Every
500
Hours
Every
1000
Hours
Every
2000
Hours
Reference Maintenance Schedule
Every
8
Hours
Coolant,
Fuel, and
Oil
Weld
Terminals
Battery
Terminals
Air
Cleaner
Air
Cleaner
Element
Labels
Check coolant, fuel, and oil levels.
Clean any fuel and/or oil spills.
Clean
Clean
Check air cleaner hoses and element.
Check and replace if necessary.
Weld
Cables
Replace any unreadable labels.
Check cables for any signs of damage and replace if necessary.
Fan Belt
Tension
Check tension for no greater than 0.5 in.
deflection.
Change Oil and
Oil Filter
Spark
Arrestor
Fuel
Filters
Check and clean
Radiator
Thermostat
Radiator
Fluid
Inside
Unit
Change in-line and primary fuel filter.
Check and replace if necessary.
Check fluid level.
Clean inside of unit.
Valve
Clearance*
Verify clearance meets specifications.
Fuel Tank Flush tank to clear out any sludge that may be present.
Slip
Rings*
Check for wear and damage.
Brushes* Check and replace if necessary.
Injectors Clean
*To be done by factory authorized service agent.
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Engine Manual
Engine Manual
Engine Manual
Engine Manual
OM-294672 Page 40
�
Complete Parts List is available at www.MillerWelds.com
Mitsubishi Engine North America
1250 Greenbriar Dr., Suite E
Addison, IL 60101
630-268-0750 https://www.mtea-us.com/
Use website to locate closest dealer. For international information, use: https://www.mhi.com/
8-3.
Cleaning Unit
Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust.
NOTICE – Use of a power washer is acceptable; however, cover or avoid vents on front panels of CST units.
OM-294672 Page 41
�
Complete Parts List is available at www.MillerWelds.com
8-4.
Servicing Air Cleaner
5
1
2
6
4
7
3
8
9
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.
�
The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with each cleaning.
The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element.
NOTICE – If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element.
Replace the safety element after servicing the primary element three times.
1 Intake Manifold
2 Service Indicator (Optional, Customer
Supplied)
3 Service Indicator Window
4 Service Indicator Reset Button
Service air cleaner element if red band appears in window. A green band means air cleaner is okay. Press button to reset indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six cleanings.
5 Housing
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove cover and dump out dust. Remove element (s).
Wipe dust from inside cover and housing with damp cloth. Reinstall safety element (if present). Reinstall cover.
Do not clean housing with air hose.
Clean primary element with compressed air only.
Air pressure must not exceed 100 psi (690 kPa). Use 1/8 in (3 mm) nozzle and keep nozzle at least 2 in (51 mm) from inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cover (dust ejector down).
OM-480 Page 1
8-5.
Battery Maintenance
Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open-circuit voltage drops to 12.4 volts DC when measured across the battery terminals.
OM-294672 Page 42
1-1. Checking Generator Brushes
3
2
Replace brushes if damaged or if brush material is at or near minimum length.
Ref 190823
1
4
1-2. Checking Generator Brush Assembly
�
Complete Parts List is available at www.MillerWelds.com
8-6.
Checking Generator Brush Assembly
aged or if brush material is at or nea minimum length. Check length from brushholder surface.
1 4 1
3
2 allen_wrench allen_set pliers needlenose knife
Stop engine and let cool.
1 Generator Brush Assembly
2 Minimum Length: 1/4 in. (6.5 mm)
3 New Length: 5/8 in. (16 mm)
Ref 205725
4 Damaged Brush
Mark and disconnect leads at brushholder assembly. Remove assembly. Press on brush to be sure springs compress.
Replace assembly if brushes are damaged or if brush material is at or near minimum length. Check length from brushholder surface.
8-7.
Inspecting And Cleaning Optional Spark Arrestor Muffler
1
3
Complete Parts List is available at www.MillerWelds.com
OM-255 254 Page 1
Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.
Stop engine and let cool.
Reinstall cleanout plug.
2
NGO’s tools/ flathead philips head wrench
3/8 in.
crescent wrench
1
OM-294672 Page 43 steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter
3
2 torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun filterwrench
OM-278215 Page 44 file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench
OM-222 Page 1
�
Complete Parts List is available at www.MillerWelds.com
8-8.
Servicing Engine Cooling System
1
Stop engine and let cool.
1 Radiator Cap Cover
2 Radiator Draincock
3 Coolant Recovery Tank
Change coolant according to engine manual.
Add coolant according to engine maintenance label.
Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot
Full levels. If recovery tank coolant level was low, also check coolant level in radiator when cold. Add coolant if level is below bottom of radiator filler neck.
2
3
8-9.
Adjusting Engine Speed
�
The engine is electronically governed. Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with adjustments may affect engine warranty.
OM-236 948 Page 1
OM-294672 Page 44
allen_wrench pliers needlenose knife
NGO’s tools/
�
Complete Parts List is available at www.MillerWelds.com
8-10. Servicing Fuel And Lubrication Systems
Stop engine and let cool.
After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Canister Fuel Filter Location
5 Fuel Filter Retaining Ring
6 In-Line Fuel Filter
To change oil and filter:
Route oil drain hose and valve through hole in base. See engine manual and engine maintenance label for oil/filter change information.
To replace canister fuel filter:
Turn filter retaining ring counterclockwise to remove. Pull filter straight down to remove.
Fill new filter with fresh fuel. Apply thin coat of fuel to gasket on new filter. Install new filter and reinstall retaining ring.
Inspect fuel lines, and replace if cracked or worn.
To drain water from fuel system:
See engine manual.
To replace in-line fuel filter:
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter, reconnect fuel lines, and reinstall clamps.
allen_wrench allen_set
NGO’s tools/ flathead philips head wrench crescent wrench
NGO’s tools/ wrench pliers crescent wrench steelbrush nutdriver chippinghammer
OM-294672 Page 45 chippinghammer stripcrimp heavy-duty workclamp chippinghammer light-duty workclamp wirecutter frontcutter solderiron solderiron stripcrimp light-duty workclamp wirecutter torque screwdriver frontcutter torque wrench socket wrench drill torque screwdriver torque wrench torque screwdriver socket wrench drill drill greasegun handream handream greasegun filterwrench strapwrench filterwrench airgun hammer handream awl greasegun file filterwrench paintbrush strapwrench strapwrench airgun hammer airgun awl hammer file awl paintbrush file qtip (swab) vicegrip paintbrush crimper feelergauge flashlight ruler qtip (swab) qtip (swab) vicegrip toothbrush punch solvent pinextractor flashlight feelergauge toothbrush ruler punch solvent pinextractor eprompuller pipewrench
OM-222 Page 1 pinextractor
OM-222 Page 1 pipewrench
OM-222 Page 1
8-11. Overload Protection
�
Complete Parts List is available at www.MillerWelds.com
6
2 1
3
4
5
Stop engine.
�
When a circuit breaker, supplementary protector, or fuse opens, it usually indicates a more serious problem exists.
Contact Factory Authorized Service
Agent.
1 Primary Fuses F2 Thru F7
Primary fuses are 30 A, 250 V, Slo Blo fuses, Miller Part No. 247869.
2 Fuse Block For Left CST(as facing front panel)
3 Fuse Block For Right CST (as facing front panel)
4 Supplementary Protector CB2
5 Supplementary Protector CB3
6 Circuit Breaker CB1
CB1 protects the engine battery circuit. If
CB1 opens, the engine will not crank. CB1 automatically resets when the fault is corrected.
CB2 protects the engine wiring harness. If
CB2 opens, the engine will not crank.
CB3 protects part of the exciter control wiring harness. If CB3 opens, generator power output may stop.
Press button to reset supplementary protector.
OM-294672 Page 46
Notes
�
Complete Parts List is available at www.MillerWelds.com
8-12. Help Displays For CST
�
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.
Help 1, 6, 7 Display
Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.
Help 2 Display
Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact a Factory Authorized Service Agent.
Help 3, 5 Display
Indicates the unit has overheated. The unit has shut down to allow
the fan to cool it (see Section 4-7). Operation will continue when the
unit has cooled.
Help 8 Display
Indicates a malfunction in the secondary power circuit of the unit. If this display is shown, contact a Factory Authorized Service Agent.
OM-294672 Page 48
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Complete Parts List is available at www.MillerWelds.com
H 9
Help 9 Display
Indicates one or both cooling fans are not operating. If this display is shown, contact a Factory Authorized Service Agent.
Help 24, 25 Display
Indicates machine has reached Duty Cycle limit (see Section 4-7).
Unit must be left on to power the fan for cooling. Duty Cycle limit will automatically reset when unit has cooled.
8-13. Troubleshooting CST
Trouble
No Output, unit completely inoperative
Blown fuses.
No weld output
Erratic or improper weld output
Fan not operating
Possible Causes
Faulty output diode(s) D1 or D2 or D3
Faulty HD1
Weld cables too small or defective.
Dirty or loose connections.
Blocked fan.
Fan Failure
8-14. Troubleshooting Generator
Remedy
Check and replace primary fuses F2 thru F7, if necessary.
Have factory authorized service agent check for shorts or opens in wiring.
Have factory authorized service agent check HD1.
Use proper size and type of weld cable. (See Section 5-8)
Clean and tighten all weld cable connections. (See Sec-
Check for and remove anything blocking fan movement.
Have factory authorized service agent check fan motor.
A. Standard Generator Power
Trouble
No generator power output at AC receptacles; weld output okay.
No generator power or weld output.
Remedy
Reset receptacle supplementary protectors (see Section 7-1).
Disconnect equipment from generator power receptacles during start-up.
Reset supplementary protector CB3 (see Section 8-11).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Have Factory Authorized Service Agent check field excitation circuit.
High output at generator power AC receptacles.
Low output at generator power AC receptacles.
Have engine Factory Authorized Service Agent check engine speed, and adjust if necessary.
OM-294672 Page 49
�
Complete Parts List is available at www.MillerWelds.com
B. Engine
Trouble
Engine will not crank.
Engine cranks but does not start.
Engine hard to start in cold weather.
Engine suddenly stops.
Engine slowly stopped and cannot be restarted.
Battery discharges between uses.
Engine uses oil during run-in period; wetstacking occurs.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-
11). Have Factory Authorized Service Agent check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-11).
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1, Fuel/Hour gauge FUEL/
HM, and control relay CR2.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR1, fuel pump, and Fuel/Hour gauge
FUEL/HM.
Air in fuel system. See engine manual.
Use Preheat switch S4 (see Section 6-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather (see Section 8-1).
Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow plug.
Check oil, fuel, and coolant levels. Automatic shutdown system stops engine if oil pressure is too
low, fuel is low, or coolant temperature is too high (see Section 5-5, 5-6, and 5-7).
Check fuel/hour meter for indication of shutdown.
Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Sec-
tion 8-11). Have Factory Authorized Service Agent check engine alternator, fuel pump, and engine
harness.
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, and the fuel pump.
See engine manual.
Check fuel level.
Check fuel/hour gauge FUEL/HM for indication of shutdown.
Check engine air and fuel filters (see Sections 8-4 and 8-10).
See engine manual.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Dry engine according to run-in procedure (see Section 11).
OM-294672 Page 50
�
Complete Parts List is available at www.MillerWelds.com
SECTION 9 – PARTS LIST
9-1.
Recommended Spare Parts
Item No.
Dia. Mkgs. Part No.
F2–F7
244290
252782
252781
213858
242882
197676
♦197679
247869
Description
Brushholder Assembly, Generator w/Leads
Filter Kit, Mitsubishi (S4l2) (Includes)
—Filter, Fuel Spin-on
—Filter, Fuel In-line 5/16x5/16 Mic 125 -175
—Filter, Lube Oil
—Element, Air Cleaner
Element, Air Cleaner Safety
Battery, 12v 570 Crk 100 Rsv Gp 35 Low Main
Fuse, SloBlo 30 Amp 250 Volt
Quantity
1
1
1
1
1
1
1
1
6
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-294672 Page 51
SECTION 10 – ELECTRICAL DIAGRAMS
OM-294672 Page 52
Figure 10-1. Circuit Diagram For Welder
293675B
OM-294672 Page 53
1-1.
Wetstacking
SECTION 11 – RUN-IN PROCEDURE
NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
11-1. Wetstacking
1
2
NOTICE – Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.
1 Welder/Generator
Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current.
NOTICE – Do not idle engine longer than necessary. Piston rings only seat correctly if engine runs at weld/power rpm, and the welder/generator is kept loaded during runin.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm.
If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures.
See the engine manual for additional engine run-in information.
OM-
OM-294672 Page 54
2
1
7
2
3
5
+
11-2. Run-In Procedure Using Load Bank Or Resistance Grid
3
2
1
6
4
7
4
3
5
+
6
Stop engine.
Do not touch hot exhaust pipe, engine parts, or load bank/grid.
Keep exhaust and pipe away from flammables.
NOTICE – Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If needed, connect load bank to 115 volts AC wall receptacle or generator auxiliary power receptacle.
2 Welder/Generator
Place A/V range switch in maximum position, A/V control in minimum position, and
Output Selector switch (if present) in either
DC position.
3 Weld Cables
4 Resistance Grid
Use grid sized for generator rated output.
Turn Off grid.
5 Voltmeter
6 Clamp-On Ammeter
Connect voltmeter and ammeter as shown, if not provided on generator.
Start engine and run for several minutes.
For Load Bank
Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator
(see nameplate, rating label, or the specifications section in this manual).
For Resistance Grid
Set grid switches and then adjust generator A/V control so load equals rated
OMnameplate, rating label, or the specifications section in this manual).
Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.
NOTICE – Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welder/generator for two hours minimum and up to four hours under load. Place A/V control in minimum position, then shut down load bank or grid to remove load. Run engine several minutes at no load.
Stop engine and let cool.
7 Engine Exhaust Pipe
Repeat procedure if wetstacking is present.
OM-294672 Page 55
SECTION 12 – 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.
12-1. Selecting Equipment
1
1 Generator Power Receptacles – Neutral
Bonded To Frame
2 3-Prong Plug From Case Grounded
Equipment
OR
3 2-Prong Plug From Double Insulated
Equipment
�
Be sure equipment has double insulated symbol and/or wording on it.
Do not use 2-prong plug unless equipment is double insulated.
2 3
12-2. Grounding Generator to Truck or Trailer Frame
1-1.
Grounding Generator To Truck Or Trailer Frame
GND/PE
1 2
3
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 Equipment Grounding Terminal (On
Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire.
�
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
OM-294672 Page 56
OM-4419 Page 1
OM-236 948 Page 1
12-3. Grounding When Supplying Building Systems
GND/PE
1 2
2
3
1 Equipment Grounding Terminal
2 Grounding Cable
Use #8 AWG or larger insulated copper wire.
3 Ground Device
�
Use ground device as stated in electrical codes.
Ground generator to system earth ground if supplying power to a premises (shop, farm) wiring system.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding
Generators.
12-4. How Much Power Does Equipment Require?
1
3
2
3
VOLTS 115
AMPS 4.5
Hz 50/60
1 Resistive Load
A light bulb is a resistive load and requires a constant amount of power.
2 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 12-8).
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.
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.
OM-294672 Page 57
OM-4419 Page 1
OM-4419 Page 1
12-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
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
Starting Watts
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
12-6. Approximate Power Requirements For Farm/Shop Equipment
Rating Farm/Shop 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
Shallow Well Pump
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
10,550
15,900
23,300
8100
23,300
35,000
46,700
3300
3150
4500
6100
2150
3100
Starting Watts
1000
1650
3400
4400
2900
10,500
1720
2575
4500
6100
8200
Running Watts
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10,700
400
550
650
800
1100
2850
3900
6800
2000
6000
8000
10,700
1000
950
1400
1600
750
1000
Running Watts
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
OM-294672 Page 58
12-7. 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
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
Starting Watts
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
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
Running Watts
350
400
600
500
900
1400
1500
1800
1100
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-294672 Page 59
12-8. Power Required To Start Motor
Motor Start
Code
KVA/HP
G
6.3
4
1
3
1 Motor Start Code
2 Running Amperage
3 Motor HP
4 Motor Voltage
VOLTS
CODE
HP
AC MOTOR
230
M
1/4
AMPS
Hz
2.5
60
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
H
Starting the motor requires 12.2 amperes.
Single-Phase Induction Motor Starting Requirements
J K L M N P
7.1
8.0
9.0
10.0
11.2
12.5
14.0
12-9. How Much Power Can Generator Supply?
1
2
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 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.
OM-294672 Page 60
OM-4419 Page 1
OM-4419 Page 1
12-10. Typical Connections To Standby Power
1. Utility Electrical
Service
2. Transfer Switch 3. Fused Disconnect
Switch (If Required)
4. Welder/Generator
Output
5. Essential Loads
Have only qualified persons perform these connections according to all applicable codes and safety practices.
Properly install, ground, and operate this equipment according to its
Owner’s Manual and national, state, and local codes.
Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed.
�
Customer-supplied equipment is required if generator will supply standby power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load from electric utility service to the generator.
Transfer load back to electric utility when service is restored.
Install correct switch (customer-supplied).
Switch rating must be same as or greater than the branch overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-supplied) 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
OM-294672 Page 61
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
A. 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 (mm 2 ) *
Current
(Amperes)
5
Load (Watts)
600
4 (25) 6 (16) 8 (10)
350 (106)
10 (6)
225 (68)
12 (4)
137 (42)
14 (2.5)
100 (30)
7
10
15
20
25
30
35
40
840
1200
1800
2400
3000
3600
4200
4800
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
75 (23)
62 (19)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
100 (30)
62 (19)
37 (11)
30 (9)
62 (19)
50 (15)
30 (9)
45
50
5400
6000
100 (30)
87 (26)
*Conductor size is based on maximum 2% voltage drop.
62 (19)
50 (15)
B. 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 (mm 2 ) *
Current
(Amperes) Load (Watts) 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5)
5 1200 700 (213) 450 (137) 225 (84) 200 (61)
7
10
15
20
1680
2400
3600
4800
800 (244)
600 (183)
450 (137)
800 (244)
550 (168)
350 (107)
275 (84)
500 (152)
350 (107)
225 (69)
175 (53)
300 (91)
225 (69)
150 (46)
100 (31)
200 (61)
125 (38)
75 (23)
60 (18)
125 (38)
100 (31)
60 (18)
25
30
35
40
45
6000
7000
8400
9600
10,800
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
50 12,000 175 (53)
*Conductor size is based on maximum 2% voltage drop.
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
125 (38)
100 (31)
100 (31)
75 (23)
75 (23)
75 (23)
OM-294672 Page 62
Effective January 1, 2023 (Equipment with a serial number preface of ND or newer)
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, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to authorized distributors that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Notifications submitted as online warranty claims must provide detailed descriptions of the fault and troubleshooting steps taken to diagnose failed parts. Warranty claims that lack the required information as defined in the Miller Service Operation Guide (SOG) may be denied by
Miller.
Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods listed below. Warranty time periods start on the delivery date of the equipment to the end-user purchaser.
1 5 Years Parts — 3 Years Labor
� Original Main Power Rectifiers Only to Include
SCRs, Diodes, and Discrete Rectifier Modules in non-inverter products
2 4 Years Parts (No Labor)
� Auto-Darkening ClearLight 2.0 Helmet Lenses
3 3 Years — Parts and Labor Unless Specified
� Auto-Darkening Helmet Lenses (No Labor)
� Engine Driven Welder/Generators (Including
EnPak) (NOTE: Engines are Warranted
Separately by the Engine Manufacturer.)
� Insight Welding Intelligence Products (Except
External Sensors)
� Inverter Power Sources
� Plasma Arc Cutting Power Sources
� Process Controllers
� Semi-Automatic and Automatic Wire Feeders
� Transformer/Rectifier Power Sources
4 2 Years — Parts and Labor
� Auto-Darkening Weld Masks (No Labor)
� Fume Extractors - Filtair 215, Capture 5, and
Industrial Collector Series
5 1 Year — Parts and Labor Unless Specified
� ArcReach Heater
� AugmentedArc, LiveArc, and MobileArc Welding Systems
� Automatic Motion Devices
� Bernard BTB Air-Cooled MIG Guns (No
Labor)
� CoolBelt, PAPR Blower, and PAPR Face
Shield (No Labor)
� Desiccant Air Dryer System
� 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, ZoneFlow Extraction Arms and Motor
Control Box
� HF Units
� ICE/XT Plasma Cutting Torches (No Labor)
� Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
� Insight Sensors
� Load Banks
� Motor-Driven Guns (except Spoolmate
Spoolguns)
� Positioners and Controllers
� Racks (For Housing Multiple Power Sources)
� Running Gear/Trailers
� Subarc Wire Drive Assemblies
� Supplied Air Respirator (SAR) Boxes and
Panels
� TIG Torches (No Labor)
� Tregaskiss Guns (No Labor)
� Water Cooling Systems
� Wireless Remote Foot/Hand Controls and
Receivers
� Work Stations/Weld Tables (No Labor)
6 6 Months — Parts
� 12 Volt Automotive-Style Batteries
7 90 Days — Parts
� Accessories (Kits)
� ArcReach Heater Quick Wrap and Air Cooled
Cables
� Canvas Covers
� Induction Heating Coils and Blankets, Cables, and Non-Electronic Controls
� MDX Series MIG Guns
� M-Guns
� MIG Guns, Subarc (SAW) Torches, and External Cladding Heads
� Remote Controls and RFCS-RJ45
� Replacement Parts (No labor)
� Spoolmate Spoolguns
Miller’s True Blue ® to:
Limited Warranty shall not apply
1.
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.)
2. 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.
3. 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.
4. Defects caused by accident, unauthorized repair, or improper testing.
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 REM-
EDIES HEREIN ARE THE SOLE AND EXCLU-
SIVE REMEDIES REGARDLESS OF THE LEGAL
THEORY. IN NO EVENT SHALL MILLER BE LI-
ABLE FOR DIRECT, INDIRECT, SPECIAL, INCI-
DENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS
OF THE LEGAL THEORY. ANY WARRANTY NOT
PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY, OR REPRESENTATION, IN-
CLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTIC-
ULAR PURPOSE, ARE EXCLUDED AND DIS-
CLAIMED 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.
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? The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record
Please complete and retain with your personal records.
Serial/Style Number Model Name
Purchase Date
Distributor
Address
City
State
(Date which equipment was delivered to original customer.)
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 Protective Equipment (PPE)
Service and Repair Replacement Parts
Training (Schools, Videos, Books)
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.
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-10
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