OM-4425 215234AX

2021−11

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welder/Generator

Big Blue 500 X



Deutz

For product information,

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

Miller Electric manufactures a full line

of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank1 2020−01
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-5. Symboles de dangers supplémentaires en relation avec linstallation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-2. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-3. Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-8. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-10. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

WARNING: Breathing diesel engine exhaust exposes you to chemicals

known to the State of California to cause cancer and birth defects or
other reproductive harm.
 Always start and operate the engine in a well-ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
 TABLE OF CONTENTS

5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-8. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-9. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Remote Amperage Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-1. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-3. Operating Optional Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-5. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-6. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-7. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-8. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2020−02

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  Indicates special instructions.
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
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid
NOTICE − Indicates statements not related to personal injury. these hazards.

1-2. Arc Welding Hazards

 Disconnect input power or stop engine before installing or
The symbols shown below are used throughout this manual servicing this equipment. Lockout/tagout input power according to
to call attention to and identify possible hazards. When you
OSHA 29 CFR 1910.147 (see Safety Standards).
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is  Properly install, ground, and operate this equipment according to
only a summary of the more complete safety information its Owner’s Manual and national, state, and local codes.
found in the Principal Safety Standards listed in Section 1-7.  Always verify the supply ground — check and be sure that input
Read and follow all Safety Standards. power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
Only qualified persons should install, operate, maintain, and grounded receptacle outlet.
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or  When making input connections, attach proper grounding conduc-
professional standing, or who by extensive knowledge, train- tor first − double-check connections.
ing and experience, has successfully demonstrated the  Keep cords dry, free of oil and grease, and protected from hot metal
ability to solve or resolve problems relating to the subject and sparks.
matter, the work, or the project and has received safety train-  Frequently inspect input power cord and ground conductor for
ing to recognize and avoid the hazards involved. damage or bare wiring – replace immediately if damaged – bare
During operation, keep everybody, especially children, away. wiring can kill.
 Turn off all equipment when not in use.
ELECTRIC SHOCK can kill.  Do not use worn, damaged, undersized, or repaired cables.
 Do not drape cables over your body.
Touching live electrical parts can cause fatal shocks  If earth grounding of the workpiece is required, ground it directly
or severe burns. The electrode and work circuit is with a separate cable.
electrically live whenever the output is on. The input  Do not touch electrode if you are in contact with the work, ground,
power circuit and machine internal circuits are also or another electrode from a different machine.
live when power is on. In semiautomatic or automat-
ic wire welding, the wire, wire reel, drive roll housing,  Use only well-maintained equipment. Repair or replace damaged
and all metal parts touching the welding wire are parts at once. Maintain unit according to manual.
electrically live. Incorrectly installed or improperly  Do not touch electrode holders connected to two welding ma-
grounded equipment is a hazard. chines at the same time since double open-circuit voltage will be
present.
 Do not touch live electrical parts.  Wear a safety harness if working above floor level.
 Wear dry, hole-free insulating gloves and body protection.  Keep all panels and covers securely in place.
 Insulate yourself from work and ground using dry insulating mats  Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground.  Insulate work clamp when not connected to workpiece to prevent
 Do not use AC weld output in damp, wet, or confined spaces, or if contact with any metal object.
there is a danger of falling.  Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
 Use AC output ONLY if required for the welding process. use.
 If AC output is required, use remote output control if present on unit.  Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
 Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp SIGNIFICANT DC VOLTAGE exists in inverter power
locations or while wearing wet clothing; on metal structures such sources AFTER stopping engine.
as floors, gratings, or scaffolds; when in cramped positions such  Stop engine on inverter and discharge input capacitors according
as sitting, kneeling, or lying; or when there is a high risk of unavoid- to instructions in Manual before touching any parts.
able 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
HOT PARTS can burn.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
 Do not touch hot parts bare handed.
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!  Allow cooling period before working on
equipment.
 Do not connect to any electrical distribution system normally sup-
plied by utility power unless a proper transfer switch and grounding  To handle hot parts, use proper tools and/or wear heavy, insu-
procedure are employed. lated welding gloves and clothing to prevent burns.

OM-4425 Page 1
  Watch for fire, and keep a fire extinguisher nearby.
FLYING METAL or DIRT can injure
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
eyes. cause fire on the hidden side.
 Welding, chipping, wire brushing, and grinding  Do not cut or weld on tire rims or wheels. Tires can explode if heat-
cause sparks and flying metal. As welds cool, ed. Repaired rims and wheels can fail. See OSHA 29 CFR
they can throw off slag. 1910.177 listed in Safety Standards.
 Wear approved safety glasses with side shields even under your  Do not weld on containers that have held combustibles, or on
welding helmet. closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
FUMES AND GASES can be Safety Standards).
hazardous.  Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
Welding produces fumes and gases. Breathing these
 Connect work cable to the work as close to the welding area as practi-
fumes and gases can be hazardous to your health.
cal to prevent welding current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
 Keep your head out of the fumes. Do not breathe the fumes.  Do not use welder to thaw frozen pipes.
 Ventilate the work area and/or use local forced ventilation at the arc  Remove stick electrode from holder or cut off welding wire at
to remove welding fumes and gases. The recommended way to contact tip when not in use.
determine adequate ventilation is to sample for the composition  Wear body protection made from durable, flame-resistant material
and quantity of fumes and gases to which personnel are exposed. (leather, heavy cotton, wool). Body protection includes oil-free
 If ventilation is poor, wear an approved air-supplied respirator. clothing such as leather gloves, heavy shirt, cuffless trousers, high
 Read and understand the Safety Data Sheets (SDSs) and the shoes, and a cap.
manufacturer’s instructions for adhesives, coatings, cleaners,  Remove any combustibles, such as a butane lighter or matches,
consumables, coolants, degreasers, fluxes, and metals. from your person before doing any welding.
 Work in a confined space only if it is well ventilated, or while  After completion of work, inspect area to ensure it is free of sparks,
wearing an air-supplied respirator. Always have a trained watch- glowing embers, and flames.
person nearby. Welding fumes and gases can displace air and
 Use only correct fuses or circuit breakers. Do not oversize or by-
lower the oxygen level causing injury or death. Be sure the breath-
pass them.
ing air is safe.
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
 Do not weld in locations near degreasing, cleaning, or spraying op-
for hot work and have a fire watcher and extinguisher nearby.
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.  Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
 Do not weld on coated metals, such as galvanized, lead, or
consumables, coolants, degreasers, fluxes, and metals.
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied NOISE can damage hearing.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded. Noise from some processes or equipment can
BUILDUP OF GAS can injure or kill. damage hearing.
 Wear approved ear protection if noise level is
 Shut off compressed gas supply when not in use. high.
 Always ventilate confined spaces or use ap-
proved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
ARC RAYS can burn eyes and skin.  Wearers of Pacemakers and other Implanted
Arc rays from the welding process produce intense Medical Devices should keep away.
visible and invisible (ultraviolet and infrared) rays  Implanted Medical Device wearers should con-
that can burn eyes and skin. Sparks fly off from the sult their doctor and the device manufacturer before going near arc
weld. welding, spot welding, gouging, plasma arc cutting, or induction heat-
 Wear an approved welding helmet fitted with a proper shade of filter ing operations.
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 CYLINDERS can explode if damaged.
Safety Standards). Compressed gas cylinders contain gas under high
 Wear approved safety glasses with side shields under your pressure. If damaged, a cylinder can explode. Since
helmet. gas cylinders are normally part of the welding
 Use protective screens or barriers to protect others from flash, process, be sure to treat them carefully.
glare, and sparks; warn others not to watch the arc.
 Protect compressed gas cylinders from excessive heat, mechani-
 Wear body protection made from durable, flame-resistant material
cal shocks, physical damage, slag, open flames, sparks, and arcs.
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high  Install cylinders in an upright position by securing to a stationary
shoes, and a cap. support or cylinder rack to prevent falling or tipping.
 Keep cylinders away from any welding or other electrical circuits.
WELDING can cause fire or explosion.  Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
Welding on closed containers, such as tanks,  Never weld on a pressurized cylinder — explosion will result.
drums, or pipes, can cause them to blow up. Sparks  Use only correct compressed gas cylinders, regulators, hoses,
can fly off from the welding arc. The flying sparks, hot and fittings designed for the specific application; maintain them
workpiece, and hot equipment can cause fires and and associated parts in good condition.
burns. Accidental contact of electrode to metal objects can cause  Turn face away from valve outlet when opening cylinder valve. Do
sparks, explosion, overheating, or fire. Check and be sure the area is not stand in front of or behind the regulator when opening the valve.
safe before doing any welding.  Keep protective cap in place over valve except when cylinder is in
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If use or connected for use.
this is not possible, tightly cover them with approved covers.  Use the proper equipment, correct procedures, and sufficient
 Do not weld where flying sparks can strike flammable material. number of persons to lift, move, and transport cylinders.
 Protect yourself and others from flying sparks and hot metal.  Read and follow instructions on compressed gas cylinders,
 Be alert that welding sparks and hot materials from welding can associated equipment, and Compressed Gas Association (CGA)
easily go through small cracks and openings to adjacent areas. publication P-1 listed in Safety Standards.
OM-4425 Page 2
1-3. Engine Hazards

BATTERY EXPLOSION can injure. EXHAUST SPARKS can cause fire.

 Always wear a face shield, rubber gloves, and  Do not let engine exhaust sparks cause fire.
protective clothing when working on a battery.  Use approved engine exhaust spark arrestor in
 Stop engine before disconnecting or connect- required areas — see applicable codes.
ing battery cables, battery charging cables (if
applicable), or servicing battery.
 Do not allow tools to cause sparks when working on a battery. HOT PARTS can burn.
 Do not use welder to charge batteries or jump start vehicles un-
less the unit has a battery charging feature designed for this pur-  Do not touch hot parts bare handed.
pose.  Allow cooling period before working on
 Observe correct polarity (+ and −) on batteries. equipment.
 Disconnect negative (−) cable first and connect it last.  To handle hot parts, use proper tools and/or wear heavy, insu-
 Keep sparks, flames, cigarettes, and other ignition sources lated welding gloves and clothing to prevent burns.
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
 Follow battery manufacturer’s instructions when working on or STEAM AND HOT COOLANT can burn.
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.  If possible, check coolant level when engine is
cold to avoid scalding.
 Always check coolant level at overflow tank, if
FUEL can cause fire or explosion. present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
 Stop engine and let it cool off before checking or  If the engine is warm, checking is needed, and there is no over-
adding fuel. flow tank, follow the next two statements.
 Do not add fuel while smoking or if unit is near  Wear safety glasses and gloves and put a rag over radiator cap.
any sparks or open flames.  Turn cap slightly and let pressure escape slowly before
 Do not overfill tank — allow room for fuel to expand. completely removing cap.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Dispose of rags in a fireproof container.
Using a generator indoors CAN KILL
 Always keep nozzle in contact with tank when fueling.
YOU IN MINUTES.
MOVING PARTS can injure.  Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
 Keep away from moving parts such as fans,  NEVER use inside a home or garage, EVEN IF
belts, and rotors. doors and windows are open.
 Only use OUTSIDE and far away from windows, doors, and
 Keep all doors, panels, covers, and guards
vents.
closed and securely in place.
 Stop engine before installing or connecting unit.
BATTERY ACID can BURN SKIN and EYES.
 Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.  Do not tip battery.
 To prevent accidental starting during servicing, disconnect
 Replace damaged battery.
negative (−) battery cable from battery.
 Flush eyes and skin immediately with water.
 Keep hands, hair, loose clothing, and tools away from moving
parts.
 Reinstall doors, panels, covers, or guards when servicing is ENGINE HEAT can cause fire.
finished and before starting engine.
 Before working on generator, remove spark plugs or injectors to  Do not locate unit on, over, or near combustible
keep engine from kicking back or starting. surfaces or flammables.
 Block flywheel so that it will not turn while working on generator  Keep exhaust and exhaust pipes way from
components. flammables.

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can  Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill. structions.
 Incorrect installation or operation of this unit  Do not modify or alter compressor or manufacturer-supplied
could result in equipment failure and personal equipment. Do not disconnect, disable, or override any safety
injury. Only qualified persons should install, op- equipment in the compressed air system.
erate, and service this unit according to its  Use only components and accessories approved by the manufac-
Owner’s Manual, industry standards, and na- turer.
tional, state, and local codes.  Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not exceed the rated output or capacity of the compressor or  Do not work under or around any equipment that is supported only
any equipment in the compressed air system. Design compressed by air pressure. Properly support equipment by mechanical
air system so failure of any component will not put people or prop- means.
erty 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.
OM-4425 Page 3
 HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
 Keep away from moving parts such as fans,
 Do not cut or gouge near flammables. belts and rotors.
 Watch for fire; keep extinguisher nearby.  Keep all doors, panels, covers, and guards
closed and securely in place.
 Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
 Before working on compressed air system,  Before working on compressed air system, turn off and lockout/
turn off and lockout/tagout unit, release pres- tagout unit, release pressure, and be sure air pressure cannot be
sure, and be sure air pressure cannot be acci- accidentally applied.
dentally applied.  Have only qualified people remove guards or covers for maint-
 Relieve pressure before disconnecting or con- enance and troubleshooting as necessary.
necting air lines.  Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
 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.
HOT PARTS can burn.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and  Do not touch hot compressor or air system
a cap when working on compressed air system. parts.
 Use soapy water or an ultrasonic detector to search for  Allow cooling period before working on
leaks−−never use bare hands. Do not use equipment if leaks are equipment.
found.
 To handle hot parts, use proper tools and/or wear heavy, insu-
 Reinstall doors, panels, covers, or guards when servicing is lated welding gloves and clothing to prevent burns.
finished and before starting unit.
 If ANY air is injected into the skin or body seek medical help im-
mediately.

BREATHING COMPRESSED AIR can in-

jure or kill.
READ INSTRUCTIONS.
 Read and follow all labels and the Owner’s
 Do not use compressed air for breathing.
Manual carefully before installing, operating, or
 Use only for cutting, gouging, and tools. servicing unit. Read the safety information at
the beginning of the manual and in each
TRAPPED AIR PRESSURE AND WHIPPING section.
HOSES can injure.  Use only genuine replacement parts from the manufacturer.
 Perform installation, maintenance, and service according to the
 Release air pressure from tools and system be- Owner’s Manuals, industry standards, and national, state, and
fore servicing, adding or changing attach- local codes.
ments, or opening compressor oil drain or oil fill
cap.

1-5. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. OVERHEATING can damage motors.

 Do not install or place unit on, over, or near  Turn off or unplug equipment before starting or
combustible surfaces. stopping engine.
 Do not install unit near flammables.  Do not let low voltage and frequency caused by
 Do not overload building wiring − be sure power supply system is low engine speed damage electric motors.
properly sized, rated, and protected to handle this unit.  Use only equipment suitable for operation on 60 or 50/60 Hz
power.
FALLING EQUIPMENT can injure.
 Use lifting eye to lift unit and properly installed FLYING SPARKS can injure.
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see  Wear a face shield to protect eyes and face.
Specifications).  Shape tungsten electrode only on grinder with
 Use correct procedures and equipment of adequate capacity to proper guards in a safe location wearing proper
lift and support unit. face, hand, and body protection.
 If using lift forks to move unit, be sure forks are long enough to  Sparks can cause fires — keep flammables away.
extend beyond opposite side of unit.
 Keep equipment (cables and cords) away from moving vehicles MOVING PARTS can injure.
when working from an aerial location.
 Follow the guidelines in the Applications Manual for the Revised  Keep away from moving parts.
NIOSH Lifting Equation (Publication No. 94−110) when manu-  Keep away from pinch points such as drive
ally lifting heavy parts or equipment. rolls.

OM-4425 Page 4
 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards.
EXPLOSION can injure.
 Put on grounded wrist strap BEFORE handling
Battery charging not present on all models. boards or parts.
 Always wear a face shield, rubber gloves, and  Use proper static-proof bags and boxes to
protective clothing when working on a battery. store, move, or ship PC boards.
 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. TILTING OF TRAILER can injure.
 Do not use welder to charge batteries or jump start vehicles un-
less it has a battery charging feature designed for this purpose.  Use tongue jack or blocks to support weight.
 Observe correct polarity (+ and −) on batteries.  Properly install welding generator onto trailer
according to instructions supplied with trailer.
 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.
READ INSTRUCTIONS.
 Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety  Read and follow all labels and the Owner’s
Standards) for additional information. Manual carefully before installing, operating, or
 Have only qualified persons do battery charging work. servicing unit. Read the safety information at
 If battery is being removed from a vehicle for charging, discon- the beginning of the manual and in each
nect negative (−) cable first and connect it last. To prevent an arc, section.
make sure all accessories are off.  Use only genuine replacement parts from the manufacturer.
 Charge lead-acid batteries only. Do not use battery charger to  Perform installation, maintenance, and service according to the
supply power to an extra-low-voltage electrical system or to Owner’s Manuals, industry standards, and national, state, and
charge dry cell batteries. local codes.
 Do not charge a frozen battery.
 Do not use damaged charging cables.
H.F. RADIATION can cause interference.
 Do not charge batteries in a closed area or where ventilation is
restricted.
 High-frequency (H.F.) can interfere with radio
 Do not charge a battery that has loose terminals or one showing navigation, safety services, computers, and
damage such as a cracked case or cover. communications equipment.
 Before charging battery, select correct charger voltage to match
battery voltage.  Have only qualified persons familiar with electronic equipment
perform this installation.
 Set battery charging controls to the Off position before connect-
ing to battery. Do not allow battery charging clips to touch each  The user is responsible for having a qualified electrician
other. promptly correct any interference problem resulting from the
installation.
 Keep charging cables away from vehicle hood, door, or moving
parts.  If notified by the FCC about interference, stop using the
equipment at once.
HIGH PRESSURE FLUIDS can injure or kill.  Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep
 Engine fuel system components can be under spark gaps at correct setting, and use grounding and shielding to
high pressure. minimize the possibility of interference.
 Before working on fuel system, turn off engine
to release pressure.
 If any fluid is injected into the skin or body seek medical help im- ARC WELDING can cause interference.
mediately.
 Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
WELDING WIRE can injure. processors, computers, and computer-driven
equipment such as robots.
 Do not press gun trigger until instructed to do
so.  Be sure all equipment in the welding area is electromagnetically
compatible.
 Do not point gun toward any part of the body,
other people, or any metal when threading  To reduce possible interference, keep weld cables as short as
welding wire. possible, close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
OVERUSE can cause OVERHEATING.
 Be sure this welding machine is installed and grounded
 Allow cooling period; follow rated duty cycle. according to this manual.
 Reduce current or reduce duty cycle before  If interference still occurs, the user must take extra measures
starting to weld again. such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
 Do not block or filter airflow to unit.

OM-4425 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:

WARNING: This product can expose you to chemicals in- WARNING: Breathing diesel engine exhaust exposes you to
cluding lead, which are known to the state of California to chemicals known to the state of California to cause cancer
cause cancer and birth defects or other reproductive and birth defects or other reproductive harm.
harm.  Always start and operate the engine in a well−ventilated
area.
For more information, go to www.P65Warnings.ca.gov.
 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 Standard for Fire Prevention During Welding, Cutting, and Other Hot
Society standard ANSI Standard Z49.1. Website: www.aws.org. Work, NFPA Standard 51B from National Fire Protection Association.
Safe Practices for the Preparation of Containers and Piping for Welding Website: www.nfpa.org.
and Cutting, American Welding Society Standard AWS F4.1 from Glob-
OSHA Occupational Safety and Health Standards for General Industry,
al Engineering Documents. Website: www.global.ihs.com.
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
Safe Practices for Welding and Cutting Containers that have Held Com- 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on
National Electrical Code, NFPA Standard 70 from National Fire Protection the Uses of TLVs and BEIs. Website: www.osha.gov.
Association. Website: www.nfpa.org and www. sparky.org.
Portable Generator Hazards Safety Alert from U.S. Consumer Product
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Safety Commission (CPSC). Website: www.cpsc.gov.
from Compressed Gas Association. Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard Applications Manual for the Revised NIOSH Lifting Equation from the
W117.2 from Canadian Standards Association. National Institute for Occupational Safety and Health (NIOSH). Web-
Website: www.csagroup.org. site: www.cdc.gov/NIOSH.
Battery Chargers, CSA Standard C22.2 NO 107.2−01 from Canadian
For Standards regulating hydraulic systems, contact the National Fluid
Standards Association. Website: www.csagroup.org.
Power Association. Website: www.nfpa.com.
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1 from American National Standards Institute. Battery Service Manual from the Battery Council International. Web-
Website: www.ansi.org. site: www.batterycouncil.org.

1-8. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM-4425 Page 6
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2020-02_fre

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on  Indique des instructions spécifiques.
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 dan-
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
gers possibles sont montrés par les symboles joints ou
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
sont expliqués dans le texte.
CHAUDES. Reportez−vous aux symboles et aux directives
AVIS − Indique des déclarations pas en relation avec des blessures ci−dessous afin de connaître les mesures à prendre pour éviter tout
personnelles. danger.

2-2. Dangers relatifs au soudage à l’arc

assises, à genoux et allongées; ou quand il y a un risque important
Les symboles présentés ci-après sont utilisés tout au long du de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
présent manuel pour attirer votre attention et identifier les ris- les appareils suivants dans l’ordre de préférence: 1) un poste à
ques de danger. Lorsque vous voyez un symbole, soyez souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
vigilant et suivez les directives mentionnées afin d’éviter tout à souder manuel (électrode enrobée) DC, 3) un poste à souder
danger. Les consignes de sécurité présentées ci−après ne manuel AC avec tension à vide réduite. Dans la plupart des cas, un
font que résumer les informations contenues dans les princi- poste courant continu de type CV est recommandé. Et, ne pas tra-
pales normes de sécurité énumérées à la section 2-7. Veuillez vailler seul!
lire et respecter toutes ces normes de sécurité.
 Ne brancher aucun système de distribution électrique norma-
L’installation, l’utilisation, l’entretien et les réparations ne lement fourni par un réseau public à moins qu’un commutateur de
doivent être confiés qu’à des personnes qualifiées. Une per- transfert et une procédure de mise à la terre adéquats ne soient
sonne qualifiée est définie comme celle qui, par la mis en place.
possession d’un diplôme reconnu, d’un certificat ou d’un  Couper l’alimentation ou arrêter le moteur avant de procéder à
statut professionnel, ou qui, par une connaissance, une for- l’installation, à la réparation ou à l’entretien de l’appareil.
mation et une expérience approfondies, a démontré avec Déverrouiller l’alimentation selon la norme OSHA 29 CFR
succès sa capacité à résoudre les problèmes liés à la tâche, 1910.147 (voir normes de sécurité).
le travail ou le projet et a reçu une formation en sécurité afin  Installer et mettre à la terre correctement cet appareil conformé-
de reconnaître et d’éviter les risques inhérents. ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Au cours de l’utilisation, tenir toute personne à l’écart et plus  Toujours vérifier la terre du cordon d’alimentation − Vérifier et
particulièrement les enfants. 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
UN CHOC ÉLECTRIQUE peut tuer. cordon est raccordée à une prise correctement mise à la terre.
 En effectuant les raccordements d’entrée fixer d’abord le conduc-
Un simple contact avec des pièces électriques peut teur de mise à la terre approprié et contre-vérifier les connexions.
provoquer une électrocution ou des blessures  Les câbles doivent être exempts d’humidité, d’huile et de graisse;
graves. L’électrode et le circuit de soudage sont protégez−les contre les étincelles et les pièces métalliques
sous tension dès que l’appareil est sur ON. Le circuit chaudes.
d’entrée et les circuits internes de l’appareil sont
 Vérifier fréquemment le cordon d’alimentation et le conducteur de
également sous tension à ce moment-là. En souda-
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
ge semi-automatique ou automatique, le fil, le le remplacer immédiatement s’il l’est −. Un fil dénudé peut en-
dévidoir, le logement des galets d’entraînement et traîner la mort.
les pièces métalliques en contact avec le fil de
 Mettre l’appareil hors tension quand on ne l’utilise pas.
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.  Ne pas utiliser des câbles usés, endommagés, sous dimension-
nés ou réparés.
 Ne jamais toucher les pièces électriques sous tension.  Ne pas enrouler les câbles autour du corps.
 Porter des gants et des vêtements de protection secs ne compor-  Si la pièce soudée doit être mise à la terre, le faire directement
tant pas de trous. avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres câble de retour.
moyens isolants suffisamment grands pour empêcher le contact  Ne pas toucher l’électrode quand on est en contact avec la pièce,
physique éventuel avec la pièce ou la terre. la terre ou une électrode provenant d’une autre machine.
 Ne pas utiliser de sortie de soudage CA dans des zones humides  Ne pas toucher des porte électrodes connectés à deux machines
ou confinées ou s’il y a un risque de chute. en même temps à cause de la présence d’une tension à vide dou-
blée.
 Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
 Si l’utilisation d’une source électrique à courant électrique s’avère conformément à ce manuel.
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.  Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
 Des précautions de sécurité supplémentaires sont requises dans
d’une tension de circuit−ouvert double.
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé-  Porter un harnais de sécurité quand on travaille en hauteur.
talliques au sol, grillages et échafaudages; dans des positions  Maintenir solidement en place tous les panneaux et capots.
OM-4425 Page 7
 Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près pos- LES ACCUMULATIONS DE GAZ
sible de la soudure. risquent de provoquer des blessures
 Isoler la pince de masse quand pas mis à la pièce pour éviter le ou même la mort.
contact avec tout objet métallique.
 Fermer l’alimentation du gaz comprimé en cas
 Ne pas raccorder plus d’une électrode ou plus d’un câble de de non utilisation.
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.  Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
 Utiliser une protection GFCI lors de l’utilisation d’appareils auxi-
liaires. Testez les prises GFCI à haute vitesse. LES RAYONS DE L’ARC peuvent
Il reste une TENSION DC NON NÉGLIGEABLE dans les provoquer des brûlures dans les
sources de soudage onduleur UNE FOIS le moteur coupé. yeux et sur la peau.
 Arrêtez le moteur sur l’onduleur et déchargez les condensateurs Le rayonnement de l’arc du procédé de soudage
d’entrée conformément aux instructions du manuel avant de tou- génère des rayons visibles et invisibles intenses
cher les pièces. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
LES PIÈCES CHAUDES peuvent soudage.
provoquer des brûlures.
 Porter un casque de soudage approuvé muni de verres filtrants
 Ne pas toucher à mains nues les parties chau- approprié pour protéger visage et yeux pour protéger votre visage
des. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
 Prévoir une période de refroidissement avant et Z87.1 énuméré dans les normes de sécurité).
de travailler à l’équipement.  Porter des lunettes de sécurité avec écrans latéraux même sous
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- votre casque.
dés et porter des gants de soudage et des vêtements épais pour  Avoir recours à des écrans protecteurs ou à des rideaux pour
éviter les brûlures. protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
DES PIECES DE METAL ou DES  Porter un équipement de protection pour le corps fait d’un matériau
SALETES peuvent provoquer résistant et ignifuge (cuir, coton robuste, laine). La protection du
des blessures dans les yeux. corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un

 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 mé- incendie ou une explosion.
talliques volantes. Pendant la période de refroidissement des Le soudage effectué sur des conteneurs fermés tels
soudures, elles risquent de projeter du laitier. que des réservoirs, tambours ou des conduites peut
 Porter des lunettes de sécurité avec écrans latéraux ou un écran provoquer leur éclatement. Des étincelles peuvent
facial. être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
LES FUMÉES ET LES GAZ peu- incendies et des brûlures. Le contact accidentel de l’électrode avec
vent être dangereux. des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
Le soudage génère des fumées et des gaz. Leur vérifier et s’assurer que l’endroit ne présente pas de danger.
inhalation peut être dangereux pour votre santé.
 Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
 Eloigner votre tête des fumées. Ne pas respirer les fumées. soigneusement avec des protections homologués.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au  Ne pas souder dans un endroit là où des étincelles peuvent tomber
niveau de l’arc pour l’évacuation des fumées et des gaz de sur des substances inflammables.
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de  Se protéger et d’autres personnes de la projection d’étincelles et
fumées et de gaz auxquelles est exposé le personnel. de métal chaud.
 Des étincelles et des matériaux chauds du soudage peuvent
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs
facilement passer dans d’autres zones en traversant de petites
approuvé.
fissures et des ouvertures.
 Lire et comprendre les fiches de données de sécurité et les instruc-  Surveiller tout déclenchement d’incendie et tenir un extincteur à
tions du fabricant concernant les adhésifs, les revêtements, les proximité.
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.  Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à  Ne pas effectuer le soudage sur des conteneurs fermés tels que
un surveillant dûment formé de se tenir à proximité. Des fumées et des réservoirs, tambours, ou conduites, à moins qu ils n aient
des gaz de soudage peuvent déplacer l’air et abaisser le niveau été préparés correctement conformément à AWS F4.1 et AWS
d’oxygène provoquant des blessures ou des accidents mortels. A6.0 (voir les Normes de Sécurité).
S’assurer que l’air de respiration ne présente aucun danger.  Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
 Ne pas souder dans des endroits situés à proximité d’opérations exemple).
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-  Brancher le câble de masse sur la pièce le plus près possible de la
mer des gaz hautement toxiques et irritants. zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier quant des risques d’électrocution, d’étincelles et d’incendie.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit  Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
bien ventilé, et en portant un respirateur à alimentation d’air. Les lées.
revêtements et tous les métaux renfermant ces éléments peuvent  En cas de non utilisation, enlever la baguette d’électrode du porte-
dégager des fumées toxiques en cas de soudage. électrode ou couper le fil à la pointe de contact.
OM-4425 Page 8
 Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
Si des BOUTEILLES sont endomma-
corps comporte des vêtements sans huile comme par ex. des gées, elles pourront exploser.
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette. Des bouteilles de gaz comprimé protecteur contien-
 Avant de souder, retirer toute substance combustible de vos po- nent du gaz sous haute pression. Si une bouteille est
ches telles qu’un allumeur au butane ou des allumettes. endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra- manipuler avec précaution.
ce d’étincelles incandescentes ni de flammes.
 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.  Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
Ne pas augmenter leur puissance; ne pas les ponter. des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
 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  Placer les bouteilles debout en les fixant dans un support station-
extincteur à proximité. naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
 Lire et comprendre les fiches de données de sécurité et les instruc-
tions du fabricant concernant les adhésifs, les revêtements, les  Tenir les bouteilles éloignées des circuits de soudage ou autres
nettoyants, les consommables, les produits de refroidissement, circuits électriques.
les dégraisseurs, les flux et les métaux.
 Ne jamais placer une torche de soudage sur une bouteille à gaz.
LE BRUIT peut affecter l’ouïe.  Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Le bruit des processus et des équipements peut
affecter l’ouïe.  Ne jamais souder une bouteille pressurisée − risque d’explosion.

 Porter des protections approuvés pour les  Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
oreilles si le niveau sonore est trop élevé. tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Les CHAMPS ÉLECTROMAGNÉTIQUES  Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
(CEM) peuvent affecter les implants mé- de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
dicaux. de l’ouverture de la vanne.
 Maintenir le chapeau de protection sur la soupape, sauf en cas
 Les porteurs de stimulateurs cardiaques et d’utilisation ou de branchement de la bouteille.
autres implants médicaux doivent rester à
distance.  Utilisez les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever, déplacer et transporter les
 Les porteurs d’implants médicaux doivent consulter leur bouteilles.
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  Lire et suivre les instructions sur les bouteilles de gaz comprimé,
gougeage, de la découpe plasma ou une opération de chauffage l’équipement connexe et le dépliant P-1 de la CGA (Compressed
par induction. Gas Association) mentionné dans les principales normes de sécu-
rité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE LE CARBURANT MOTEUR peut pro-

peut provoquer des blessures. voquer un incendie ou une explosion.
 Toujours porter une protection faciale, des  Arrêter le moteur avant de vérifier le niveau de
gants en caoutchouc et vêtements de protec- carburant ou de faire le plein.
tion lors d’une intervention sur la batterie.
 Ne pas faire le plein en fumant ou proche d’une source d’étincel-
les ou d’une flamme nue.
 Arrêter le moteur avant de débrancher ou de brancher des câbles  Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
de batterie, des câbles de chargeur de batterie (le cas échéant) ou pour son expansion.
de batterie d’entretien.
 Faire attention de ne pas renverser de carburant. Nettoyer tout
 Eviter de provoquer des étincelles avec les outils en travaillant sur carburant renversé avant de faire démarrer le moteur.
la batterie.  Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou
remplissage.
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. Les PIÈCES MOBILES peuvent causer
 Observer la polarité correcte (+ et −) sur les batteries.
des blessures.

 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en  S’abstenir de toucher des parties mobiles telles
dernier lieu. que des ventilateurs, courroies et rotors.

 Les sources d’étincelles, flammes nues, cigarettes et autres  Maintenir fermés et verrouillés les portes, panneaux,
sources d’inflammation doivent être maintenues à l’écart des recouvrements et dispositifs de protection.
batteries. Ces dernières produisent des gaz explosifs en  Arrêter le moteur avant d’installer ou brancher l’appareil.
fonctionnement normal et en cours de charge.  Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
pannage, faire retirer les portes, panneaux, recouvrements ou
 Suivre les instructions du fabricant de la batterie lors d’opérations
dispositifs de protection uniquement par du personnel qualifié.
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’-  Pour empêcher tout démarrage accidentel pendant les travaux
informations. d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-4425 Page 9
 Ne pas approcher les mains, cheveux, vêtements lâches et outils cisé autrement dans la section maintenance du manuel du
des organes mobiles. moteur).
 Remettre en place les portes, panneaux, recouvrements ou  Si le moteur est chaud et que le liquide doit être vérifié, opérer com-
dispositifs de protection à la fin des travaux d’entretien et avant de me suivant.
mettre le moteur en marche.  Mettre des lunettes de sécurité et des gants, placer un torchon sur
 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la le bouchon du radiateur.
mise en route accidentelle du moteur.  Dévisser le bouchon légèrement et laisser la vapeur s’échapper
 Bloquer le volant moteur pour éviter sa rotation lors d’une avant d’enlever le bouchon.
intervention sur le générateur.
L’utilisation d’un groupe autonome
LES ÉTINCELLES À L’ÉCHAPPEMENT à l’intérieur PEUT VOUS TUER EN
peuvent provoquer un incendie. QUELQUES MINUTES.
 Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.  Les fumées d’un groupe autonome contient du
 Utiliser uniquement un pare-étincelles monoxyde de carbone. C’est un poison invisi-
approuvé − voir codes en vigueur. ble et inodore.
 JAMAIS utiliser dans une maison ou garage, même avec les por-
LES PIÈCES CHAUDES peuvent tes et fenêtres ouvertes.
provoquer des brûlures.  Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
 Ne pas toucher des parties chaudes à mains
nues.
 Prévoir une période de refroidissement avant de L’ACIDE DE LA BATTERIE peut pro-
travailler à l’équipement. voquer des brûlures dans les YEUX et
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- sur la PEAU.
dés et porter des gants de soudage et des vêtements épais pour  Ne pas renverser la batterie.
éviter les brûlures.
 Remplacer une batterie endommagée.
LA VAPEUR ET LE LIQUIDE DE  Rincer immédiatement les yeux et la peau à l’eau.
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures. LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
 Il est préférable de vérifier le liquide de refroi-
dissement une fois le moteur refroidi pour éviter  Ne pas placer l’appareil sur, au-dessus ou à
de se brûler. proximité de surfaces inflammables.
 Toujours vérifier le niveau de liquide de refroidissement dans le  Tenir à distance les produits inflammables de l’échappement.
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même MÉTAL CHAUD provenant du découpage
la mort. ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.

 Ne pas découper ou gouger à proximité de produits inflammables.

 Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un  Attention aux risques d’incendie: tenir un extincteur à proximité.
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes L’AIR COMPRIMÉ risque de provoquer
industrielles et aux codes nationaux, d’état ou locaux. des blessures ou même la mort.
 Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir  Avant d’intervenir sur le circuit d’air comprimé,
le circuit d’air comprimé de telle sorte que la défaillance couper l’alimentation électrique, verrouiller
d’un composant ne risque pas de provoquer un accident matériel et étiqueter l’appareil, détendre la pression
ou corporel. et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
 Avant d’intervenir sur le circuit d’air comprimé, couper
 Détendre la pression avant de débrancher ou
l’alimentation électrique, verrouiller et étiqueter l’appareil,
de brancher des canalisations d’air.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
 Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
 Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil comprimé, les branchements et les flexibles en recherchant tout
fonctionne. Seul un personnel qualifié est autorisé, et appliquant signe de détérioration, de fuite et d’usure.
les consignes du fabricant.  Ne pas diriger un jet d’air vers soi−même ou vers autrui.
 Ne pas modifier ou altérer le compresseur ou les équipements  Pour intervenir sur un circuit d’air comprimé, porter un équipement
fournis par le fabricant. Ne pas débrancher, désactiver ou de protection tel que des lunettes de sécurité, des gants de cuir,
neutraliser les équipements de sécurité du circuit d’air comprimé. une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
 Utiliser uniquement des composants et accessoires homologués
 Pour rechercher des fuites, utiliser de l’eau savonneuse ou
par le fabricant.
un détecteur à ultrasons, jamais les mains nues. En cas
 Se tenir à l’écart de tout point présentant un danger de pincement de détection de fuite, ne pas utiliser l’équipement.
ou d’écrasement créé par l’équipement raccordé au circuit d’air  Remettre les portes, panneaux, recouvrements ou dispositifs
comprimé. de protection quand l’entretien est terminé et avant de mettre
 Ne pas intervenir sous ou autour d’un équipement qui n’est en marche l’appareil.
soutenu que par la pression pneumatique. Soutenir l’équipement  En cas d’injection d’air dans la peau ou le corps, demander
de façon appropriée par un moyen mécanique. immédiatement une assistance médicale.
OM-4425 Page 10
 détendre la pression et s’assurer que le circuit d’air ne peut être
L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance.
de provoquer des blessures ou même
la mort.  Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
 Ne pas inhaler d’air comprimé. s’il y a lieu, des travaux d’entretien et de dépannage.
 Utiliser l’air comprimé uniquement pour  Remettre en place les portes, panneaux, recouvrements ou
découper ou gouger ainsi que pour l’outillage dispositifs de protection à la fin des travaux d’entretien et avant
pneumatique. de mettre le moteur en marche.

Une PRESSION D’AIR RÉSIDUELLE DES PIÈCES CHAUDES peuvent

ET DES FLEXIBLES QUI FOUETTENT provoquer des brûlures graves.
risquent de provoquer des blessures.
 Ne pas toucher de pièces chaudes
 Détendre la pression pneumatique des outils et du compresseur ou du circuit d’air.
circuits avant d’entretenir, ajouter ou changer  Prévoir une période de refroidissement avant
des accessoires et avant d’ouvrir le bouchon d’intervenir sur l’équipement.
de vidange ou de remplissage d’huile
 Ne pas toucher aux pièces chaudes, utiliser les outils recom-
du compresseur. mandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.

Les PIÈCES MOBILES peuvent causer

des blessures. LIRE LES INSTRUCTIONS.

 S’abstenir de toucher des parties mobiles telles  Lire et appliquer les instructions sur les
que des ventilateurs, courroies et rotors. étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
 Maintenir fermés et verrouillés les portes, l’appareil. Lire les informations de sécurité au
panneaux, recouvrements et dispositifs début du manuel et dans chaque section.
de protection.
 N’utiliser que les pièces de rechange recommandées par le
 Ne pas approcher les mains, cheveux, vêtements lâches et outils constructeur.
des organes mobiles.
 Effectuer l’installation, l’entretien et toute intervention selon les
 Avant d’intervenir sur le circuit d’air comprimé, couper manuels d’utilisateurs, les normes nationales, provinciales et de
l’alimentation électrique, verrouiller et étiqueter l’appareil, l’industrie, ainsi que les codes municipaux.

2-5. Symboles de dangers supplémentaires en relation avec linstallation, le fonctionnement et la

maintenance

Risque D’INCENDIE OU LE SURCHAUFFEMENT peut

D’EXPLOSION. endommager le moteur électrique.
 Ne pas placer l’appareil sur, au-dessus ou  Arrêter ou déconnecter l’équipement avant de
à proximité de surfaces inflammables. démarrer ou d’arrêter le moteur.
 Ne pas installer l’appareil à proximité de pro-
duits inflammables.  Ne pas laisser tourner le moteur trop lentement sous risque d’en-
dommager le moteur électrique à cause d’une tension et d’une fré-
 Ne pas surcharger l’installation électrique − s’assurer que l’ali- quence trop faibles.
mentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.  Utiliser uniquement des équipements adéquats pour un fonction-
nement avec une alimentation de 50/60 ou de 60 Hz.

LES ÉTINCELLES PROJETÉES

LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures. peuvent provoquer des blessures.
 Utiliser l’anneau de levage pour lever l’appareil  Porter un écran facial pour protéger le visage et
et les accessoires correctement installées les yeux.
seuls, PAS les bouteilles de gaz. Ne pas dé-  Affûter l’électrode au tungstène uniquement à
passer le poids nominal maximal de l’œilleton la meuleuse dotée de protecteurs. Cette ma-
(voir les spécifications). nœuvre est à exécuter dans un endroit sûr lors-
que l’on porte l’équipement homologué de pro-
 Utilisez les procédures correctes et des équipements d’une ca-
pacité appropriée pour soulever et supporter l’appareil. tection du visage, des mains et du corps.
 En utilisant des fourches de levage pour déplacer l’unité, s’assu-  Les étincelles risquent de causer un incendie − éloigner toute
rer que les fourches sont suffisamment longues pour dépasser substance inflammable.
du côté opposé de l’appareil.
 Tenir l’équipement (câbles et cordons) à distance des véhicules Les PIÈCES MOBILES peuvent
mobiles lors de toute opération en hauteur.
causer des blessures.
 Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage  Ne pas s’approcher des organes mobiles.
manuelle de pièces ou équipements lourds.  Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.

OM-4425 Page 11
 LA SORTIE DE RECHARGE et L’EXP-  Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
LOSION DE LA BATTERIE peuvent  Ne pas obstruer les passages d’air du poste.
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les LES CHARGES ÉLECTROSTATI-
modèles. QUES peuvent endommager les
 Toujours porter une protection faciale, des gants en caoutchouc circuits imprimés.
et vêtements de protection lors d’une intervention sur la batterie.  Établir la connexion avec la barrette de terre
 Arrêter le moteur avant de débrancher ou de brancher des câbles de avant de manipuler des cartes ou des pièces.
batterie, des câbles de chargeur de batterie (le cas échéant) ou de  Utiliser des pochettes et des boîtes antistatiques pour stocker,
batterie d’entretien. déplacer ou expédier des cartes de circuits imprimes.
 Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie. UNE REMORQUE QUI BASCULE peut
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou provoquer des blessures.
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  Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
cet usage.
 Observer la polarité correcte (+ et −) sur les batteries.  Installer convenablement le poste sur la remor-
 Débrancher le câble négatif (−) en premier lieu. Le rebrancher en que comme indiqué dans le manuel s’y rappor-
dernier lieu. tant.
 Les sources d’étincelles, flammes nues, cigarettes et autres sources
d’inflammation doivent être maintenues à l’écart des batteries. Ces LIRE LES INSTRUCTIONS.
dernières produisent des gaz explosifs en fonctionnement normal et
en cours de charge.  Lire et appliquer les instructions sur les
 Suivre les instructions du fabricant de la batterie lors d’opérations sur étiquettes et le Mode d’emploi avant
une batterie ou à proximité de celle−ci. Voir le manuel de service de l’installation, l’utilisation ou l’entretien de
batterie (indiqué dans Normes de sécurité) pour plus d’informations. l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
 Les opérations de charge de batterie ne doivent être effectuées que
par des personnes qualifiées.  N’utiliser que les pièces de rechange recommandées par le
 Pour enlever la batterie d’un véhicule pour la recharge, débrancher constructeur.
tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour  Effectuer l’installation, l’entretien et toute intervention selon les
éviter un arc, s’assurer que tous les accessoires sont débranchés. manuels d’utilisateurs, les normes nationales, provinciales et de
 Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur l’industrie, ainsi que les codes municipaux.
de batterie pour alimenter un autre circuit électrique basse tension ou
pour charger des batteries sèches. LE RAYONNEMENT HAUTE FRÉ-
 Ne pas charger une batterie gelée. QUENCE (H.F.) risque de provoquer
 Ne pas utiliser de câbles de charge endommagés. des interférences.
 Ne pas charger des batteries dans un espace fermé ou en l’absence
d’une ventilation.  Le rayonnement haute fréquence (H.F.) peut
 Ne pas charger une batterie dont les bornes sont desserrées ou provoquer des interférences avec les équipe-
présentant une détérioration comme par exemple un boîtier ou un ments de radio−navigation et de communica-
couvercle fissuré. tion, les services de sécurité et les ordinateurs.
 Avant de charger une batterie, sélectionner la tension de charge
 Demander seulement à des personnes qualifiées familiarisées avec
correspondant à la tension de la batterie.
des équipements électroniques de faire fonctionner l’installation.
 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  L’utilisateur est tenu de faire corriger rapidement par un électricien
se touchent pas. qualifié les interférences résultant de l’installation.
 Ranger les câbles de charge à distance du capot, des portes et des  Si le FCC signale des interférences, arrêter immédiatement l’appareil.
pièces mobiles du véhicule.  Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES LIQUIDES PRESSURISÉS peuvent  Maintenir soigneusement fermés les portes et les panneaux des
blesser ou tuer. sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
 Les composants du système d’alimentation interférences éventuelles.
peuvent contenir du carburant sous pression
élevée. LE SOUDAGE À L’ARC risque de
 Avant d’intervenir sur le système d’alimentation de carburant, provoquer des interférences.
arrêter le moteur pour dépressuriser le système.  L’énergie électromagnétique risque de provoquer
 En cas d’injection de tout liquide sous la peau ou dans le corps, des interférences pour l’équipement électronique
solliciter une aide médicale sur le champ. sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
LES FILS DE SOUDAGE peuvent  Veiller à ce que tout l’équipement de la zone de soudage soit com-
provoquer des blessures. patible électromagnétiquement.
 Ne pas appuyer sur la gâchette avant d’en  Pour réduire la possibilité d’interférence, maintenir les câbles de
avoir reçu l’instruction. soudage aussi courts que possible, les grouper, et les poser aussi
 Ne pas diriger le pistolet vers soi, d’autres per- bas que possible (ex. par terre).
sonnes ou toute pièce mécanique en enga-  Veiller à souder à une distance de 100 mètres de tout équipement
geant le fil de soudage. électronique sensible.

L’EMPLOI EXCESSIF peut  Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
SURCHAUFFER L’ÉQUIPEMENT.
 En cas d’interférences après avoir pris les mesures précédentes, il in-
 Laisser l’équipement refroidir ; respecter le fac- combe à l’utilisateur de prendre des mesures supplémentaires telles
teur de marche nominal. 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.
OM-4425 Page 12
2-6. Proposition californienne 65 Avertissements
Pour les moteurs diesel :
AVERTISSEMENT : ce produit peut vous exposer à des pro-
duits chimiques tels que le plomb, reconnus par l’État de AVERTISSEMENT : les gaz d’échappement de moteurs diesel
Californie comme cancérigènes et sources de malformations vous exposent à des produits chimiques, reconnus par l’État
ou d’autres troubles de la reproduction. de Californie comme cancérigènes et sources de malfor-
Pour plus d’informations, consulter www.P65Warnings.ca.gov. mations 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’ex-
térieur.
 Ne pas modifier ni altérer le système d’échappement.
 Ne pas faire tourner le moteur au ralenti, sauf si nécess-
aire.
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 Standard for Fire Prevention During Welding, Cutting, and Other Hot
Society standard ANSI Standard Z49.1. Website: www.aws.org. Work, NFPA Standard 51B from National Fire Protection Association.
Safe Practices for the Preparation of Containers and Piping for Welding Website: www.nfpa.org.
and Cutting, American Welding Society Standard AWS F4.1 from Glob-
OSHA Occupational Safety and Health Standards for General Industry,
al Engineering Documents. Website: www.global.ihs.com.
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
Safe Practices for Welding and Cutting Containers that have Held Com- 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on
National Electrical Code, NFPA Standard 70 from National Fire Protection the Uses of TLVs and BEIs. Website: www.osha.gov.
Association. Website: www.nfpa.org and www. sparky.org.
Portable Generator Hazards Safety Alert from U.S. Consumer Product
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Safety Commission (CPSC). Website: www.cpsc.gov.
from Compressed Gas Association. Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard Applications Manual for the Revised NIOSH Lifting Equation from the
W117.2 from Canadian Standards Association. National Institute for Occupational Safety and Health (NIOSH). Web-
Website: www.csagroup.org. site: www.cdc.gov/NIOSH.
Battery Chargers, CSA Standard C22.2 NO 107.2−01 from Canadian
For Standards regulating hydraulic systems, contact the National Fluid
Standards Association. Website: www.csagroup.org.
Power Association. Website: www.nfpa.com.
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1 from American National Standards Institute. Battery Service Manual from the Battery Council International. Web-
Website: www.ansi.org. site: www.batterycouncil.org.

2-8. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs 3. Ne pas courber et ne pas entourer les câbles autour de votre
électromagnétiques (CEM) à certains endroits. Le courant issu d’un corps.
soudage à l’arc (et de procédés connexes, y compris le soudage par 4. Maintenir la tête et le torse aussi loin que possible du matériel du
points, le gougeage, le découpage plasma et les opérations de circuit de soudage.
chauffage par induction) crée un champ électromagnétique (CEM)
5. Connecter la pince sur la pièce aussi près que possible de la
autour du circuit de soudage. Les champs électromagnétiques produits
soudure.
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs 6. Ne pas travailler à proximité d’une source de soudage, ni
d’implants médicaux doivent être prises: par exemple, des restrictions s’asseoir ou se pencher dessus.
d’accès pour les passants ou une évaluation individuelle des risques 7. Ne pas souder tout en portant la source de soudage ou le
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir.
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
En ce qui concerne les implants médicaux :
soudage:
Les porteurs d’implants doivent d’abord consulter leur médecin avant
1. Rassembler les câbles en les torsadant ou en les attachant avec de s’approcher des opérations de soudage à l’arc, de soudage par
du ruban adhésif ou avec une housse. points, de gougeage, du coupage plasma ou de chauffage par
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les induction. Si le médecin approuve, il est recommandé de suivre les pro-
câbles d’un côté et à distance de l’opérateur. cédures précédentes.

OM-4425 Page 13
  Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
 Some symbols are found only on CE products.

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.

Safe90 2017−04

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2017−04

Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

<12.4 V
Read Owner’s Manual for battery maintenance information.

/ + − + −
Safe117 2014−06

0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.

Safe54 2017−04

50 h std
After the first 50 hours of operation, change the engine oil and filter.

Safe55 2012−05

Never use generator inside a home or garage, even if doors and win-
dows are open.

Safe87 2012−07

Only use generator outside and far away from windows, doors, and
vents.

Safe88 2012−07

OM-4425 Page 14
  Complete Parts List available at www.MillerWelds.com
3-2. Miscellaneous Symbols And Definitions

 Some symbols are found only on CE products.

A Amperage Contactor On Engine

V Voltage
Work Connection
Idle (Slow)

Direct Current Negative

Run (Fast)
(DC)

X
Positive Engine Start
Duty Cycle (Engine RPM)

Protective Earth

I2 Rated Welding
Current
(Ground) Engine Stop

Circuit Breaker

U2 Conventional
Load Voltage
Supplementary
Protector
Engine Oil

U0 Rated No−Load
Voltage (OCV)
Output Fuel

I Current
Off Filter

Engine
On
n Rated Load Temperature
Speed
Increase or Battery (Engine)
Decrease of

n0 Rated No−Load Quantity

Speed (Rotating)
Engine Belt

n1 Rated Idle Speed

Panel/Local

Manual Cleaning

Hz
Do Not Switch
Hertz While Welding
Spark Arrestor
Remote
Hours
Air Filter
Read Operator’s
Clock, Time Manual
Switch
Air Flow
Electrode
Hour Meter Connection
Check Air Cleaner

Alternating Welding (General)

Current (AC) Check
Shielded Metal Injectors/Pump
Arc Welding
Single Phase (SMAW)
Check Valve
Gas Tungsten Arc Clearance
Welding (GTAW) /
Three Phase Tungsten Inert
Gas (TIG) Certified/Trained
Welding Mechanic
Engine−Driven
3−Phase Starting Aid
Alternator with Call for
(Preheat) Maintenance
Rectifier

OM-4425 Page 15
  Complete Parts List available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. 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 1045F (405C).
Maximum
Welding Weld Output Rated Welding Open- Generator Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
500 A, 30 Volts DC
40% Duty Cycle
Single-Phase, Deutz D2011L03i
IEC Rating Air/Oil-Cooled, Three
95 4 kVA/kW, 34/17 A, 25 gal
CC/DC 55 − 500 A 400 A, 36 Volts DC, Cylinder, 31.9 HP
120/240 V AC, (95 L)
100% Duty Cycle 50/60 Hz Diesel Engine
450 A, 38 Volts DC,
60% Duty Cycle

OM-4425 Page 16
  Complete Parts List available at www.MillerWelds.com
4-5. Dimensions, Weights, And Operating Angles

Dimensions
60 in. (1524 mm)
Height
(to top of muffler)

28.5 in. (724 mm) G

(mtg. brackets turned in)
Width
30.75 in. (781 mm)
(mtg. brackets turned out)
Depth 65.125 in. (1654 mm)
A 65.125 in. (1654 mm) ! Do not exceed tilt angles or engine could
be damaged or unit could tip.
B* 56 in. (1422 mm) ! Do not move or operate unit where it could
C* 46.5 in. (1181) tip.
A
D* 9.625 in. (244 mm) B C
E 27.5 in. (699 mm)
F 1 in. (25 mm)
G 29.8125 in. (757 mm)
H
9/16 in. (14 mm) Dia. 30°
H
4 Holes
D 30°
* With mounting brackets in center 20°
position. Dimensions vary with
location of mounting brackets. 20°
F
Weight E
w/ Deutz No fuel: 1600 lb (726 kg) 802 161-A
F3L2011 W/fuel: 1775 lb (805 kg)

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

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.
IP23S 2014−06

B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range

−40 to 104°F (−40 to 40°C) −4 to 131°F (−20 to 55°C)

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07

OM-4425 Page 17
  Complete Parts List available at www.MillerWelds.com
4-7. Duty Cycle And Overheating
100% Duty Cycle At 400 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

215 084-A

4-8. Volt-Ampere Curves

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
100 other settings fall between the
Ranges: curves shown.
230 − Max
170 − 365
80
110 − 225
70 − 130
DC VOLTS

55 − 85
60

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
215 081-A

OM-4425 Page 18
  Complete Parts List available at www.MillerWelds.com
4-9. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

2.50
2.25
2.00
1.75
US Gal./Hr.

1.50
1.25
1.00
0.75
0.50
0.25 IDLE

0.00
0 50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE

199 032-A

4-10. AC Generator Power Curve

The AC power curve shows the
generator power in amperes avail-
able at the 120 and 240 volt
receptacles.

150 300

125 250
AC VOLTS

100 200

75 150

50 100

25 50

0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE

193 018

OM-4425 Page 19
  Complete Parts List available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welder/Generator

Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)

OR OR
18 in.
18 in. (460 mm)
(460 mm)

Location/Mounting

Welding Bolting
Unit In Unit In
Place 2 Place 3
2

OR

OR

Tools Needed: 1 1

9/16 in. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

 Go to MillerWelds.com for more ! Do not weld on base. Welding on To Bolt Unit In Place:
information on truck installations. base can cause fuel tank fire or ex- Remove hardware securing the four
Movement plosion. Weld only on the four mounting brackets to the base. Reverse
mounting brackets or bolt unit brackets and reattach to base with original
! Do not move or operate unit where down. hardware.
it could tip. NOTICE − Do not mount unit by supporting Mount unit to truck or trailer with 1/2 in. (12
the base only at the four mounting bracket- mm) or larger hardware (not supplied).
 See Section 5-3 for lifting eye rating. s. Use cross-supports to adequately sup-
port unit and prevent damage to base. To Weld Unit In Place:
Airflow Clearance
1 Cross-Supports Weld unit to truck or trailer only at the four
NOTICE − Do not install unit where air flow
is restricted or engine may overheat. 2 Mounting Brackets (Supplied) mounting brackets.
Mount unit on flat surface or use cross-sup-
Location/Mounting
ports to support base. Secure unit with
! Always securely fasten welding mounting brackets.
generator onto transport vehicle or 3 1/2 in Bolt And Washer (Minimum −
trailer and comply with all DOT and Not Supplied)
other applicable codes. 4 3/8-16 x 1 in. Screws (Supplied)

OM-4425 Page 20
  Complete Parts List available at www.MillerWelds.com
5-2. Grounding Generator To Truck Or Trailer Frame
! Always ground generator
frame to vehicle frame to pre-
vent 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 insu-
late the welder/generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
1 2 frame as shown.

GND/PE
! Use GFCI protection when
operating auxiliary equip-
ment. If unit does not have
GFCI receptacles, use GFCI-
protected extension cord.
Do not use GFCI receptacles
to power life support equip-
ment.
3
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 insu-
lated copper wire.

 Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
rot_grnd1 2012−03 − 800 652-D

5-3. Using Lifting Eye

1 Lifting Eye
2 Nut
3 Carriage Bolt
1
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in.
2 carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:
3

907185-TP1

OM-4425 Page 21
  Complete Parts List available at www.MillerWelds.com
5-4. Installing Exhaust Pipe
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in. Exhaust1 2008−01 Ref. 803 604 / Ref. 215 664

5-5. Connecting The Battery

Tools Needed:
1/2 in.
Conn_batt1 2014−11 802 168-E / S-0756-C

NOTICE − Lead acid batteries discharge Battery is most easily accessed through  Never start the engine when the
when stored in any temperature. Units that the rear panel. Remove battery access cables are loose or poorly connected
are stored should have the battery panel from rear panel. Connect battery, to the battery terminals.
recharged every three months and before negative cable last. Reinstall battery ac-  Never disconnect the battery while
being put into service. To preserve opti- cess panel. the engine is running.
mum battery performance and life,
 Do not allow the battery cables to  Never use a quick battery charger to
recharge battery in storage when the
touch opposing terminals. When con- start the engine.
open−circuit voltage drops to 12.4 volts
necting the battery cables attach the
DC when measured across the battery  Do not charge battery with Engine
positive (+) cable to the positive (+)
terminals. Control switch On.
battery terminal first, followed by neg-
! Connect negative (−) cable last. ative (−) cable to negative (−) battery  Always disconnect the negative (−)
NOTICE − Wait two minutes after engine terminal. battery cable before charging battery.
shutdown before disconnecting battery or
engine controller may be damaged.

OM-4425 Page 22
  Complete Parts List available at www.MillerWelds.com
5-6. Engine Prestart Checks

Full
 Follow run-in procedure
in engine manual. If un-
burned fuel and oil collect
Diesel in exhaust pipe during
run-in, see Section 11.

Full

907185-TP2

 Check all engine fluids daily. Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
 To improve cold weather starting:
Engine must be cold and on a level surface. pipe during run-in, see Section 11.
Use Starting Aid switch (see Section
Automatic shutdown system stops engine if
Fuel 6-1).
oil pressure is too low or engine tempera-
ture is too high. NOTICE − Do not use gasoline. Gasoline
Keep battery in good condition. Store
will damage engine.
 This unit has a low oil pressure shut- battery in warm area.
down switch. However, some condi- Add fresh diesel fuel before starting (see
tions may cause engine damage before engine maintenance label for fuel specifica- Use fuel formulated for cold weather
the engine shuts down. Check oil level tions). Leave filler neck empty to allow room (diesel fuel can gel in cold weather).
often and do not use the oil pressure for expansion. Contact local fuel supplier for fuel in-
shutdown system to monitor oil level. formation.
Engine stops if fuel level is low.
NOTICE − Diesel engines in Miller equip-
Oil Use correct grade oil for cold weather
ment are meant to operate optimally at mod-
erate to rated load. Using light or no load for After fueling, check oil with unit on level sur- (see Section 8-1).
extended periods of time may cause wet- face. If oil is not up to full mark on dipstick,
stacking or engine damage. add oil (see maintenance label).

OM-4425 Page 23
  Complete Parts List available at www.MillerWelds.com
5-7. Weld Output Terminals

! Turn off power before connecting to

weld output terminals.

! Do not use worn, damaged, under-

sized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.

Ref. 907185 TP1

5-8. Connecting Weld Output Cables

2
6
3
1

Tools Needed: 5
3/4 in. (19 mm)

803 778-B

! Turn off power before connecting to cable terminal and copper bar. Make
sure that the surfaces of the weld cable
5 Weld Cable Terminal
weld output terminals. 6 Copper Bar
terminal and copper bar are clean.
! Failure to properly connect weld ca- 1 Correct Weld Cable Connection Remove supplied nut from weld output ter-
bles may cause excessive heat and 2 Incorrect weld Cable Connection minal. Slide weld cable terminal onto weld
start a fire, or damage your machine. output terminal and secure with nut so that
3 Weld Output Terminal weld cable terminal is tight against copper
 Do not place anything between weld 4 Supplied Weld Output Terminal Nut bar.
connecting weld output cables 3−2010

OM-4425 Page 24
  Complete Parts List available at www.MillerWelds.com
5-9. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08

5-10. Connecting To Remote Amperage Adjust Receptacle RC13

1 Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1 RC13 (see Section 6-3).

Ref. 154 862-A / 048 720-K / 907185 TP1

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  Complete Parts List available at www.MillerWelds.com
SECTION 6 − OPERATING WELDER/GENERATOR

6-1. Front Panel Controls (See Section 6-2)

11 12 5 4 3
6 7

13

8 1 2
9

10

240 162-D / Ref. 907185 TP1

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6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls 4 Engine Temperature Gauge TIG welding (see max OCV note under Weld
1 Starting Aid Switch Normal temperature is 212 − 239°F (100 − Controls).
Use switch to energize starting aid for cold 115°C). Engine stops if temperature exceeds When switch is in the Stick position, the max
weather starting (see starting instructions fol- 270°F (132°C). OCV circuit resets Amperage Adjust Control
lowing). 5 Engine Oil Pressure Gauge R1 to maximum when the arc breaks.
2 Engine Control Switch Normal pressure is 30 − 60 psi (207 − 414 Also in the Stick position, the arc drive (dig)
kPa). Engine stops if pressure is below 10 psi circuit provides additional amperage during
Use switch to start and stop engine. low voltage (short arc length conditions) to
(69 kPa).
NOTICE − Diesel engines in MILLER equip- prevent “sticking” electrodes.
ment are meant to operate optimally at moder- Weld Controls
When switch is in Scratch Start TIG position,
ate to rated load. Using light or no load for ex-
tended periods of time may cause wetstack-
 Max OCV Control Circuit: This unit has the max OCV and arc drive (dig) circuits are
a max OCV control circuit that resets Am- disabled and OCV changes when the control
ing or engine damage. is adjusted.
perage Adjust control R1 to maximum
To Start: when the arc breaks. When an arc is 9 Amperage Adjust Switch And Remote
NOTICE − Do not use ether or other starting struck, weld output control returns to the Amperage Adjust Receptacle
fluids. Using starting fluids voids warranty. R1 front panel or combination front panel/
remote control setting. The Amperage Connect optional remote control to RC13
 If engine does not start, let engine come Adjust control adjusts amperage only (See Section 5-10). Use switch to select front
to a complete stop before attempting re- when welding and does not adjust open- panel or remote amperage control. For re-
start. mote control, place switch in Remote position
circuit voltage.
and connect remote control to Remote Am-
Above 325 F (05 C): turn Engine Control perage Adjust receptacle RC13 (see Sec-
switch to Start. Release Engine Control The max OCV circuit is disabled when the
Stick/TIG Selection switch is in Scratch tions 5-10 and 6-3).
switch when engine starts.
Start TIG position (see item 8). 10 Polarity Switch (Optional)
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting NOTICE − Do not switch under load.
Aid switch, turn Engine Control switch to 6 Ampere Range Switch Use switch to change weld output. Select ei-
Start. Release Engine Control switch and NOTICE − Do not switch under load. ther DC Electrode Positive (DCEP) or DC
Starting Aid switch when engine starts. Use switch to select weld amperage range. Electrode Negative (DCEN).
To Stop: turn Engine Control switch to Off For most welding applications, use lowest Weld Meters
position. amperage range possible to help prevent arc 11 AC/DC Voltmeter (Optional)
Engine Gauges And Meters outages.
Voltmeter displays voltage at the weld output
3 Engine Fuel/Hour Gauge 7 Amperage Adjust Control terminals, but not necessarily the welding arc
Use gauge to monitor engine running time for Control adjusts amperage within range se- due to resistance of cable and connections.
scheduling maintenance and to determine lected by Ampere Range switch. Weld output 12 AC/DC Ammeter (Optional)
cause of engine shutdowns. would be about 168 A DC with controls set as
shown (50% of 110 to 225 A). Ammeter displays amperage output of the
Use gauge to check fuel level. Engine stops unit.
if fuel level is low.  The numbers around the control are for 13 Battery Voltmeter (Optional)
To check fuel level when engine is not run- reference only and do not represent an
actual percentage value. Use gauge to check battery voltage and moni-
ning, turn Engine Control switch to Run or tor the engine charging system. The meter
Run/Idle position. 8 Stick/TIG Selection Switch should read about 14 volts dc when the en-
See Section 6-5 for complete fuel/hour gauge Use switch to disable the max OCV circuit gine is running, and about 12 volts dc when
information. and the arc drive (dig) circuit for scratch start the engine is stopped.

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6-3. Remote Amperage Control (Optional)
1 Remote Amperage Adjust
Receptacle RC13
1 Connect optional remote control to
RC13 (see Section 5-10).

Example: Combination Remote Amperage Control (Stick) In Example:

Range = 110 to 225 A DC
Percentage Of Range = 50%
Max = About 168 A DC (50% of 110 to 225)

Max (168 A DC)

Min (90 A DC)

Set Switches Set Range Set Control Adjust Optional Remote Control
Ref. 154 862-A / Ref. 181 711-A / 803 602

6-4. Weld Control/Arc Condition Information Label

 Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.

212 944-B

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6-5. Fuel/Hour Gauge Descriptions

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  Complete Parts List available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Export Auxiliary Power Receptacles

4
3

European Receptacle

Australian Receptacle
2
1
5

South African Receptacle

238 127-A / 805 259-A

! Use GFCI protection when operat- Maximum output is 2.4 kVA/kW from GFCI1
and 4 kVa/kW from RC1.
does not work. Place circuit breaker switch
in the On position to reset breaker.
ing auxiliary equipment. If unit does
not have GFCI receptacles, use Maximum combined output of all recep-
GFCI-protected extension cord. Do tacles is 4 kVA/kW.  At least once a month, press test but-
not use GFCI receptacles to power ton. If ELCB is working properly, power
EXAMPLE: If 13 A is drawn from RC1, only will be disconnected. Reset breaker.
life support equipment. 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) = 4 220V 16A AC European
! Unplug power cord before attempt-
4.0 kVA/kW Receptacle RC1
ing to service accessories or tools.
2 Circuit Breaker CB2 5 240 V 15 A AC Australian
1 120V 15/20A AC Receptacle GFCI1 CB2 protects GFCI1 from overload. If a cir- Receptacle RC1
Receptacles supply 60 Hz single-phase cuit breaker opens, the receptacle does not
6 240 V 15 A AC South African
power at weld/power speed. work. Press CB2 to reset breaker. Receptacle RC1
3 Earth Leakage Circuit Breaker
! Test GFCI monthly. See Section 7-2 ELCB1  If a circuit breaker continues to open,
for GFCI information and for reset- ELCB1 protects RC1 from Earth leakage contact Factory Authorized Service
ting and testing procedures. fault. If circuit breaker opens the receptacle Agent.

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7-2. GFCI Receptacle Information, Resetting, And Testing

 Alternate location for red

and green indicator LEDs.

2
5

 Orientation of receptacle may be different in other applications.

RotGFCI1 2018-12

! Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
Resetting GFCI Receptacles
ing auxiliary equipment. If unit does If a GFCI fault occurs, stop engine and dis-
disconnect power to the faulty equipment.
not have GFCI receptacles, use connect equipment from GFCI receptacle.
GFCI-protected extension cord. Do A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks Check for damaged or wet tools, cords,
not use GFCI receptacle to power plugs, etc. connected to the receptacle.
life support equipment. not related to ground faults. Reset and test
GFCI receptacle according to the following Start engine, place engine control switch in
! Unplug power cord before attempt- procedures. RUN position, and press GFCI Reset but-
ton. Reconnect equipment to GFCI recep-
ing to service accessories or tools.
A solid green LED indicates power to the tacle. If GFCI Reset button pops out again,
1 120 V 20 A AC GFCI Receptacle check the equipment and repair or replace
GFCI. A solid red LED indicates that the
2 GFCI Receptacle Test Button GFCI has been tripped. if faulty.
3 GFCI Receptacle Reset Button
Resetting/Testing GFCI Receptacle Testing GFCI Receptacles
4 Red GFCI Indicator Light (LED)
5 Green GFCI Indicator Light (LED) Start engine and place engine control
! Test GFCI monthly. switch in Run position. Press the GFCI Test
 Red and Green indicator lights may be button. The GFCI Reset button should pop
combined in a single LED. ! If Red LED blinks, stop using GFCI out.
GFCI Receptacles receptacle and have a Factory Au-
thorized Service Agent replace it. Press the GFCI Reset button.
GFCI receptacles protect the user from
electric shock if a ground fault occurs in Have a Factory Authorized Service
equipment connected to the receptacle. A ! Extension cords with bad insulation Agent replace GFCI if any of the follow-
ground fault occurs when electrical current or of extended length can allow ing occur:
takes the shortest path to ground (which enough leakage current to trip the GFCI does not trip when tested
could be through a person) rather than fol- GFCI circuit. Reset and test as Red LED blinks
low its intended safe path. follows. GFCI does not reset.

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  Complete Parts List available at www.MillerWelds.com
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label

DEUTZ

DEUTZ Service:
http://www.deutzamericas.com
To ensure rapid, efficient service support, you
should initially contact your nearest DEUTZ ser-
vice distributor or dealer.
They are staffed with highly qualified parts, ser-
vice and engine specialists to handle your differ-
ent needs.
The DEUTZ Service Desk enhances this sup-
port and can be contacted by completing and
submitting the Service Support Form. Customer
in the US and CANADA can also contact the ser-
vice desk by calling our toll free number,
1-800-241-9886.
Our normal hours of operation are from 8:00 AM
to 6:00 PM Monday through Friday EST. You
may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us,
please have available or provide specific engine
information (serial number, model number etc.)
as shown on the Service Support Form.

237 352-K

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8-2. Routine Maintenance

! Stop engine before maintaining.

Recycle engine  See Engine Manual and Maintenance Label
fluids. for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference

* To be done by Factory Authorized Service Agent

Every Section 5-6,

8 FUEL 8-8
WATER
Hours

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

Every
50
Hours

 Weld Terminals

Every Section 8-5

100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 8-7

Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Every
500
Hours

 Weld Cables
Every NOTICE − Change engine Section 8-8,
1000 oil and filter after initial 50 8-4 and En-
Hours to 75 hours of use. gine Manual

 Oil  Oil Filter  Fuel Filter

FUEL
OR

SLUDGE
 Slip Rings*  Inside Unit Valve Clearance*  Drain Sludge
 Brushes*

Every
3000
Hours

 Injectors*

Every
6000
Hours
or 5
Years
 Engine Timing Belt
 = Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion.

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8-3. Operating Optional Oil Pan Heater

1 Optional Oil Heater Plug

Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Heater rated at 300 watts.

! Do not run engine while oil

pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
120 volts AC receptacle when en-
gine oil is warm to eliminate possib-
ility of oil coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.

! The area near the oil pan

heater gets hot.
Disconnect plug to turn off heater.

803 602 / 907185 TP1

8-4. Checking Generator Brushes

! Stop engine and let cool.

1 Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Minimum Length:
5/8 in. (16 mm) Replace brushes if damaged or if brush
New Length: material is at or near minimum length.
1-1/4 in. (32 mm)

1
Replace
Damaged Brushes
GenBrush1 2012−05 / Ref 190 823

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8-5. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
4 the clean side of the filter while clean-
ing and the possibility of filter damage
1 makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
2 to clean or replace the primary ele-
ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
Optional the safety element after servicing the pri-
mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
Customer Supplied)
3 Service Indicator Window
5 6 7 8 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). Re-
place primary element if damaged. Re-
place primary element yearly or after six
Optional cleanings.
5 Housing
9
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 ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm)
from element. ! 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 ele-
ment if it has holes or damaged gaskets.
Blow Inspect Reinstall primary element and cover
(dust ejector down).

aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B

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8-6. 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.

8-7. Inspecting And Cleaning Optional Spark Arrestor Muffler

! Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
2 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.
1

Tools Needed:
3/8 in.

907185 TP1 / Ref. 236 970

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8-8. Adjusting Engine Speed
! Stop engine and let cool.
 For operation at high altitude,
engine may require adjust-
ments. If adjustment is neces-
sary, contact engine manufac-
turer’s Factory Authorized Ser-
vice Agent.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
1850 rpm Max. Place Stick/TIG switch in Stick
(61.6 Hz) position.
1250 rpm Standard Models:
(41.6 Hz) 1 Engine Speed Adjustment
Screw
2 Locking Nut
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
 Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
Standard Models 3 Throttle Rod
4 Locknut
5 Throttle Stop Screw
6 Throttle Lever
Loosen locknuts. Place engine
2 control switch in Run/Idle position.
Turn throttle rod until engine runs at
1 idle speed. Tighten locknuts.
NOTICE − To prevent solenoid
damage, be sure a 1/8 in. (3 mm)
gap exists between the throttle stop
screw and throttle lever when the
solenoid is held in the energized
position.
7 Engine Speed Adjustment
Models With Automatic Idle (Optional) Screw
8 Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
4 3 engine runs at weld/power speed.
Tighten locknut.

 Do not set engine speed higher

than specified.

! Stop engine.
Close door.
5
6
7

8
Tools Needed:

3/8, 7/16 in.

803 644 / Ref. 800 159

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8-9. Servicing Fuel And Lubrication Systems

Tools Needed:

907185 TP2

! Stop engine and let cool. in base. See engine manual and engine
maintenance label for oil/filter change in-
To replace secondary fuel filter:
See engine manual.
! After servicing, start engine and formation.
Close doors.
check for fuel leaks. Stop engine, To drain sludge from fuel tank:
To drain water from fuel system:
tighten connections as necessary,
and wipe up spilled fuel. Open primary fuel filter petcock and drain
! Beware of fire. Do not smoke and
1 Oil Filter water into metal container. Close petcock keep sparks and flames away from
when water-free fuel flows. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose in an environmentally-safe manner.
3 Oil Fill Cap To replace primary fuel filter: Do not leave unit unattended while
draining fuel tank.
4 Primary Fuel Filter (Fuel/Water Sepa-
rator) Turn filter counterclockwise. Remove filter. ! Properly lift unit and secure in a level
5 Petcock Apply thin coat of fuel to gasket on new filter. position. Use adequate blocks or
Fill filter with fuel. Install filter and turn clock- stands to support unit while drain-
6 Secondary Fuel Filter ing fuel tank.
wise. Bleed air from fuel system according
7 Fuel Tank Sludge Drain Valve to engine manual. Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
To change oil and filter:
Inspect fuel line, and replace if cracked or to open sludge drain valve. Close valve
Route oil drain hose and valve through hole worn. when sludge has drained. Remove hose.

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8-10. Overload Protection
! Stop engine.
 When a supplementary protector, cir-
cuit breaker or fuse opens, it usually
indicates a more serious problem ex-
ists. Contact Factory Authorized Ser-
vice Agent.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely. If
F2 opens, weld output is low or stops en-
tirely. 4 kVA/kW generator power is still
available.
2 1 3 Circuit Breaker CB4 (Not Shown)
4 Circuit Breaker CB10 (Not Shown)
5 Supplementary Protector CB11
6 Supplementary Protector CB12
7 Supplementary Protector CB13

7 8 Circuit Breaker CB14 (Not Shown)

6 CB4 protects the welding arc drive (dig)
5 circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault is
corrected.
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the engine weld control cir-
cuit. On CC models, if CB11 opens the
max OCV circuit does not work and open
circuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 6-2).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available.
CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Press button to reset.

Ref. 907185 TP1

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8-11. Troubleshooting

A. Welding

Trouble Remedy

No weld output; generator power output Check position of Ampere Range switch.
okay at AC receptacles.

Check position of optional Polarity switch.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Check fuse F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
integrated rectifier SR2 and the rotor.

Have Factory Authorized Service Agent check brushes and slip rings, and weld excitation circuit.

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Sec-
tion 8-10).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

Erratic weld output. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check OCV control circuit.

Low weld output. Check engine speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section
frequently during low voltage (short arc 8-10). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions. SR5.

Low open-circuit voltage. Check engine speed, and adjust if necessary.

Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).

No remote fine amperage control. Place Amperage Adjust switch in Remote position.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Reset supplementary protector CB11 (see Section 8-10). Have Factory Authorized Service Agent check
control relay CR7.

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

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B. Standard Generator Power

Trouble Remedy

No generator power output at AC recep- Reset receptacle supplementary protectors.

tacles; weld output okay.

Reset GFCI receptacle.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 .

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

High output at generator power AC Check engine speed, and adjust if necessary.
receptacles.

Have Factory Authorized Service Agent adjust generator power field current resistor R3.

Low output at generator power AC Check engine speed, and adjust if necessary.
receptacles.

Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
integrated rectifier SR1, resistor R3, and capacitor C9.

C. Engine

Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-10).
Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1.

Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check fuel/hour gauge, control relay CR5, fuel pump, and fuel
solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch is released. is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

Have Factory Authorized Service Agent check fuel/hour gauge, and control relay CR5.

Engine hard to start in cold weather. Use starting aid switch (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).

Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 8-5 and 8-9).

See engine manual.

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Trouble Remedy
Battery discharges between uses. 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).

Engine idles, but does not come up to Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
weld speed (models with idle option
only).

Check for obstructed throttle solenoid.

Engine does not run at idle speed Place Stick/TIG Selection switch in Stick position.
(models with idle option only).

Check for obstructed throttle solenoid.

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11).
wetstacking occurs.

SECTION 9 − PARTS LIST

9-1. Recommended Spare Parts
Dia. Part
Mkgs. No. Description Quantity
. . . . . . . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246988 . . Kit, Filter Deutz 2011 (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 066217 . . . . Filter, Fuel Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192744 . . Filter, Fuel Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216959 . . Belt, Blower (Deutz 2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . . 1
♦Optional

OM-4425 Page 42
Notes

OM-4425 Page 43
 SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For Welder/Generator

OM-4425 Page 44
 238628-E

OM-4425 Page 45
 SECTION 11 − RUN-IN PROCEDURE
run_in1 2014−09

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
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 volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
2 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
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,
1 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-4425 Page 46
11-2. Run-In Procedure Using Load Bank Or Resistance Grid

2
1

4
3

S-0683 / S-0684

! Stop engine. 3 Weld Cables voltage and current of the generator

4 Resistance Grid (see nameplate, rating label, or the
! Do not touch hot exhaust pipe, en-
specifications section in this manual).
gine parts, or load bank/grid. Use grid sized for generator rated output.
! Keep exhaust and pipe away from Turn Off grid. Check generator and meters after first five
flammables. minutes then every fifteen minutes to be
5 Voltmeter sure generator is loaded properly.
NOTICE − Do not perform run-in 6 Clamp-On Ammeter
procedure at less than 20 volts weld output NOTICE − Check oil level frequently during
and do not exceed duty cycle or equipment Connect voltmeter and ammeter as run-in; add oil if needed.
damage may occur. shown, if not provided on generator.
Start engine and run for several minutes. It is recommended to run the welder/gener-
1 Load Bank ator for two hours minimum and up to four
Turn all load bank switches Off. If needed, For Load Bank hours under load. Place A/V control in
connect load bank to 115 volts ac wall Set load bank switches and then adjust minimum position, then shut down load
receptacle or generator auxiliary power generator A/V control so load equals bank or grid to remove load. Run engine
receptacle. rated voltage and current of generator several minutes at no load.
(see nameplate, rating label, or the
2 Welder/Generator ! Stop engine and let cool.
specifications section in this manual).
Place A/V range switch in maximum posi-
For Resistance Grid 7 Engine Exhaust Pipe
tion, A/V control in minimum position, and
Output Selector switch (if present) in either Set grid switches and then adjust gen- Repeat procedure if wetstacking is pres-
DC position. erator A/V control so load equals rated ent.

OM-4425 Page 47
 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 Generator Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
1 Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
 Be sure equipment has double
insulated symbol and/or word-
ing on it.
! Do not use 2-prong plug un-
less equipment is double
insulated.

2 3

OR

gen_pwr 2018−06 − ST-800 577

12-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

800 652-D

! Always ground generator frame to 3 Metal Vehicle Frame frame. Always connect a ground
vehicle frame to prevent electric wire from the generator equipment
Connect cable from equipment ground grounding terminal to bare metal on
shock and static electricity hazards. terminal to metal vehicle frame. Use #8 the vehicle frame as shown.
! Also see AWS Safety & Health Fact AWG or larger insulated copper wire.
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Gen-  Electrically bond generator frame to ve- ! Use GFCI protection when operat-
erators. hicle frame by metal-to-metal contact. ing auxiliary equipment. If unit does
not have GFCI receptacles, use
1 Equipment Grounding Terminal (On ! Bed liners, shipping skids, and GFCI-protected extension cord. Do
Front Panel) some running gear insulate the not use GFCI receptacles to power
2 Grounding Cable (Not Supplied) welder/generator from the vehicle life support equipment.

OM-4425 Page 48
12-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #8 AWG or larger insulated
1 2 copper wire.
GND/PE 3 Ground Device
 Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
2 3 Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

ST-800 576-B

12-4. How Much Power Does Equipment Require?

1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires
approximately six times more power
while starting the motor than when
3 running (see Section 12-8).
VOLTS 115 3 Rating Data
2 AMPS 4.5
1 Hz 50/60 Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its
running power requirement in watts.
3 4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.

S-0623

OM-4425 Page 49
12-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10,550 2850
3 HP 15,900 3900
5 HP 23,300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23,300 6000
7-1/2 HP 35,000 8000
10 HP 46,700 10,700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

12-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10,500 2800
Farm Duty Motors Std. (e.g. Conveyors, Feed 1/3 HP 1720 720
Augers, Air Compressors) 1/2 HP 2575 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10,550 2850
3 HP 15,900 3900
5 HP 23,300 6800
Farm Duty Motors High Torque 1-1/2 HP 8100 2000
(e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, 5 HP 23,300 6000
Bunk Feeders)
7-1/2 HP 35,000 8000
10 HP 46,700 10,700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050
OM-4425 Page 50
12-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment Rating Starting Watts Running Watts
Hand Drill 1/4 in. 350 350
3/8 in. 400 400
1/2 in. 600 600
Circular Saw 6-1/2 in. 500 500
7-1/4 in. 900 900
8-1/4 in. 1400 1400
Table Saw 9 in. 4500 1500
10 in. 6300 1800
Band Saw 14 in. 2500 1100
Bench Grinder 6 in. 1720 720
8 in. 3900 1400
10 in. 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10,500 2800
Electric Chain Saw 1-1/2 HP, 12 in. 1100 1100
2 HP, 14 in. 1100 1100
Electric Trimmer Standard 9 in. 350 350
Heavy Duty 12 in. 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in. 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 GPH 600 200
Centrifugal Pump 900 GPH 900 500
Floor Polisher 3/4 HP, 16 in. 4500 1400
1 HP, 20 in. 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-4425 Page 51
12-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start G H J K L M N P
Code
KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

1 Motor Start Code

2 Running Amperage
3 Motor HP
4 Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
4 AC MOTOR find kVA/HP. If code is not listed,
2 multiply running amperage by six to
1 VOLTS 230 AMPS 2.5 find starting amperage.
3 CODE M Hz 60
Step 2: Find Motor HP and Volts.
HP 1/4 PHASE 1
Step 3: Determine starting amper-
age (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 amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.

S-0624

12-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.

1 2 5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
2 supply.

Ref. ST-800 396-A / S-0625

OM-4425 Page 52
12-10. Typical Connections To Supply Standby Power

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.
! Properly install, ground, and
operate this equipment ac-
cording to its Owner’s
Manual and national, state,
and local codes.
! Do not connect to any elec-
1 2 3 4 trical distribution system
Fused normally supplied by utility
Utility Welding power unless a proper trans-
Disconnect
Electrical Transfer Switch Generator fer switch and grounding
Switch
Service Output procedure are employed.
(If Required)
 Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
5 ages.
1 Utility Electrical Service
Essential 2 Transfer Switch (Double-Throw)
Loads
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
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 wir-
ing 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 volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 12-4).

OM-4425 Page 53
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*

Current
Load (Watts) 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5)
(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm2)*

Current
Load (Watts) 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5)
(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-4425 Page 54
 Effective January 1, 2021
(Equipment with a serial number preface of NB 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 * TIG Torches (No Labor)
Warranty Questions? below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to * Tregaskiss Guns (No Labor)
authorized distributors that new Miller equipment sold after the * Water Cooling Systems
Call effective date of this limited warranty is free of defects in material * Wireless Remote Foot/Hand Controls and Receivers
and workmanship at the time it is shipped by Miller. THIS * Work Stations/Weld Tables (No Labor)
1-800-4-A-MILLER WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER 5. 6 Months — Parts
for your local WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* 12 Volt Automotive-Style Batteries
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Miller distributor. Within the warranty periods listed below, Miller will repair or replace
6. 90 Days — Parts
* Accessories (Kits)
any warranted parts or components that fail due to such defects in * ArcReach Heater Quick Wrap and Air Cooled Cables
material or workmanship. Miller must be notified in writing within * Canvas Covers
Your distributor also gives thirty (30) days of such defect or failure, at which time Miller will * Induction Heating Coils and Blankets, Cables, and
you ... provide instructions on the warranty claim procedures to be Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
Service * MDX Series MIG Guns
provide detailed descriptions of the fault and troubleshooting steps
* M-Guns
You always get the fast, taken to diagnose failed parts. Warranty claims that lack the
required information as defined in the Miller Service Operation * MIG Guns, Subarc (SAW) Torches, and External
reliable response you Cladding Heads
need. Most replacement Guide (SOG) may be denied by Miller.
* Remote Controls and RFCS-RJ45
parts can be in your Miller shall honor warranty claims on warranted equipment listed * Replacement Parts (No labor)
hands in 24 hours. below in the event of a defect within the warranty coverage time * Spoolmate Spoolguns
Support periods listed below. Warranty time periods start on the delivery
Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months
Need fast answers to the
after the equipment is shipped to a North American distributor, or 1. Consumable components; such as contact tips,
tough welding questions? 18 months after the equipment is shipped to an international cutting nozzles, contactors, brushes, relays, work
Contact your distributor. distributor, whichever occurs first. station table tops and welding curtains, or parts that
The expertise of the fail due to normal wear. (Exception: brushes and
1. 5 Years Parts — 3 Years Labor relays are covered on all engine-driven products.)
distributor and Miller is
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
there to help you, every Diodes, and Discrete Rectifier Modules
step of the way. such as engines or trade accessories. These items are
2. 3 Years — Parts and Labor Unless Specified covered by the manufacturer’s warranty, if any.
* Auto-Darkening Helmet Lenses (No Labor) 3. Equipment that has been modified by any party other than
* Engine Driven Welder/Generators Miller, or equipment that has been improperly installed,
(NOTE: Engines are Warranted Separately by the improperly operated or misused based upon industry
Engine Manufacturer.) standards, or equipment which has not had reasonable
* Insight Welding Intelligence Products (Except External and necessary maintenance, or equipment which has
Sensors) been used for operation outside of the specifications for
* Inverter Power Sources the equipment.
* Plasma Arc Cutting Power Sources 4. Defects caused by accident, unauthorized repair, or
* Process Controllers improper testing.
* Semi-Automatic and Automatic Wire Feeders MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Transformer/Rectifier Power Sources AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
3. 2 Years — Parts and Labor THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
* Auto-Darkening Weld Masks (No Labor) The exclusive remedies for warranty claims are, at Miller’s
* Fume Extractors − Capture 5, Filtair 400 and Industrial option, either: (1) repair; or (2) replacement; or, if approved in
Collector Series writing by Miller, (3) the pre-approved cost of repair or
4. 1 Year — Parts and Labor Unless Specified replacement at an authorized Miller service station; or (4)
* ArcReach Heater payment of or credit for the purchase price (less reasonable
* AugmentedArc and LiveArc Welding Systems depreciation based upon use). Products may not be returned
* Automatic Motion Devices without Miller’s written approval. Return shipment shall be at
* Bernard BTB Air-Cooled MIG Guns (No Labor) customer’s risk and expense.
* CoolBelt (No Labor) The above remedies are F.O.B. Appleton, WI, or Miller’s
* Desiccant Air Dryer System authorized service facility. Transportation and freight are the
* Field Options customer’s responsibility. TO THE EXTENT PERMITTED BY
(NOTE: Field options are covered for the remaining LAW, THE REMEDIES HEREIN ARE THE SOLE AND
warranty period of the product they are installed in, EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
or for a minimum of one year — whichever is THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
greater.) DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls (Except RFCS-RJ45) CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
* Fume Extractors − Filtair 130, MWX and SWX Series,
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
ZoneFlow Extraction Arms and Motor Control Box
WARRANTY, GUARANTY, OR REPRESENTATION,
* HF Units INCLUDING ANY IMPLIED WARRANTY OF
* ICE/XT Plasma Cutting Torches (No Labor) MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Induction Heating Power Sources, Coolers PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
(NOTE: Digital Recorders are Warranted MILLER.
Separately by the Manufacturer.)
Some US states do not allow limiting the duration of an implied
* Load Banks
warranty or the exclusion of certain damages, so the above
* Motor-Driven Guns (except Spoolmate Spoolguns) limitations may not apply to you. This warranty provides
* PAPR Blower Unit (No Labor) specific legal rights, and other rights may be available
* Positioners and Controllers depending on your state. In Canada, some provinces provide
* Racks (For Housing Multiple Power Sources) additional warranties or remedies, and to the extent the law
* Running Gear/Trailers prohibits their waiver, the limitations set out above may not
* Subarc Wire Drive Assemblies apply. This Limited Warranty provides specific legal rights, and
* Supplied Air Respirator (SAR) Boxes and Panels other rights may be available, but may vary by province.

mil dom warr 2021-01

Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Register your product at www.millerwelds.com/support/

product−registration

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 Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books)
Appleton, WI 54914 USA
Welding Process Handbooks International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
To locate a Distributor or Service Agency visit USA & Canada FAX: 920-735-4134
www.millerwelds.com or call 1-800-4-A-Miller International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2021 Miller Electric Mfg. LLC 2021−01