Miller 145DX, 185DX, 145 User Manual

OM-248 551B

2010−10

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator



Blue Star Series

145, 145DX, 185DX

ENGLISH

ESPAÑOL

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

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. Hydraulic Hazards 4....................................................................

1-5. Compressed Air Hazards 4..............................................................

1-6. Additional Symbols For Installation, Operation, And Maintenance 5.............................

1-7. California Proposition 65 Warnings 6......................................................

1-8. Principal Safety Standards 7.............................................................

1-9. EMF Information 7.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 8..........................

2-1. Signification des symboles 8.............................................................

2-2. Dangers relatifs au soudage à l’arc 8......................................................

2-3. Dangers existant en relation avec le moteur 10..............................................

2-4. Dangers liés à l’hydraulique 11............................................................

2-5. Dangers liés à l’air comprimé 12...........................................................

2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 13.....

2-7. Proposition californienne 65 Avertissements 14..............................................

2-8. Principales normes de sécurité 15.........................................................

2-9. Informations relatives aux CEM 15.........................................................

SECTION 3 − DEFINITIONS 16..................................................................

SECTION 4 − SPECIFICATIONS 16..............................................................

4-1. 145 Models Weld, Power, And Engine Specifications 16.......................................

4-2. 185DX Model Weld, Power, And Engine Specifications 16.....................................

4-3. Dimensions, Weights, And Operating Angles 17..............................................

4-4. Duty Cycle 17..........................................................................

4-5. Volt-Ampere Curves 18..................................................................

4-6. Fuel Consumption 19....................................................................

4-7. Generator Power Curve 20...............................................................

SECTION 5 − INSTALLATION 21................................................................

5-1. Installing Welding Generator 21...........................................................

5-2. Grounding Generator To Truck Or Trailer Frame 21...........................................

5-3. Grounding Generator When Supplying Building Systems 22....................................

5-4. Fuel Valve Positions 22..................................................................

5-5. Engine Prestart Checks 23...............................................................

5-6. Connecting The Battery (As Applicable) 24..................................................

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

5-8. Connecting To Weld Output Terminals 25...................................................

5-9. Selecting Weld Cable Sizes* 25...........................................................

SECTION 6 − OPERATING THE WELDING GENERATOR 26........................................

6-1. Engine Controls 26......................................................................

6-2. Front Panel Controls 27..................................................................

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 28............................................

7-1. Generator Power Panel Receptacles 28....................................................

SECTION 8 − MAINTENANCE 29................................................................

8-1. Routine Maintenance 29.................................................................

8-2. Maintenance Label 30...................................................................

8-3. Servicing Air Cleaner 31.................................................................

8-4. Changing Fuel Filter (DX Models Only) 31...................................................

TABLE OF CONTENTS

8-5. Changing Oil 32........................................................................

8-6. Adjusting Engine Speed (145 Standard Model) 32............................................

8-7. Adjusting Engine Speed (DX Models) 33....................................................

SECTION 9 − TROUBLESHOOTING 34..........................................................

SECTION 10 − PARTS LIST 36..................................................................

10-1. Recommended Spare Parts 36............................................................

SECTION 11 − ELECTRICAL DIAGRAMS 38......................................................

SECTION 12 − GENERATOR POWER GUIDELINES 40............................................

SECTION 13 − STICK WELDING (SMAW) GUIDELINES 47.........................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2010−03

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-8. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded
equipment is a hazard.

 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on

unit.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

 Always verify the supply ground — check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

 Frequently inspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-248 551 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

 Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

 Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

 Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire haz­ards.

 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

 After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

 Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use ap-

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.

 Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off

from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres­sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder — explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and
associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-248 551 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can injure.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables, battery charging cables (if
applicable), or servicing battery.

 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles un-

less the unit has a battery charging feature designed for this pur­pose.

 Observe correct polarity (+ and −) on batteries.
 Disconnect negative (−) cable first and connect it last.
 Keep sparks, flames, cigarettes, and other ignition sources

away from batteries. Batteries produce explosive gases during
normal operation and when being charged.

 Follow battery manufacturer’s instructions when working on or

near a battery.

BATTERY CHARGING OUTPUT can injure.

(Battery charging feature not present on all models.)

 Have only qualified persons do battery charging work.
 Charge lead-acid batteries only. Do not use battery charger to

supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.

 Do not charge a frozen battery.
 Do not use damaged charging cables.
 Do not charge a battery that has loose terminals or one showing

damage such as a cracked case or cover.

 Before charging battery, select correct charger voltage to match

battery voltage.

 Set battery charging controls to the Off position before connect-

ing to battery. Do not allow battery charging clips to touch each
other.

 Keep charging cables away from vehicle hood, door, or moving

parts.

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

 Do not add fuel while smoking or if unit is near

any sparks or open flames.

 Do not overfill tank — allow room for fuel to expand.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.

MOVING PARTS can injure.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.
 Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

HOT PARTS can burn.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).

 If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

 Only use OUTSIDE and far away from windows, doors, and

vents.

BATTERY ACID can BURN SKIN and EYES.

 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

 Keep away from moving parts such as fans,

belts, and rotors.

 Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.
 Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator

components.

OM-248 551 Page 3

1-4. Hydraulic Hazards

HYDRAULIC EQUIPMENT can injure
or kill.

 Incorrect installation or operation of this unit

could result in equipment failure and personal
injury. Only qualified persons should install, op­erate, and service this unit according to its
Owner’s Manual, industry standards, and na­tional, state, and local codes.

 Do not exceed the rated output or capacity of the hydraulic pump

or any equipment in the hydraulic system. Design hydraulic sys­tem so failure of any hydraulic component will not put people or
property at risk.

 Before working on hydraulic system, turn off and lockout/tagout

unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.

 Do not work on hydraulic system with unit running unless you are

a qualified person and following the manufacturer’s instructions.

 Do not modify or alter hydraulic pump or manufacturer-supplied

equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.

 Use only components/accessories approved by the manufac-

turer.

 Keep away from potential pinch points or crush points created by

equipment connected to the hydraulic system.

 Do not work under or around any equipment that is supported

only by hydraulic pressure. Properly support equipment by
mechanical means.

HYDRAULIC FLUID can injure or kill.

 Before working on hydraulic system, turn off and

lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.

 Relieve pressure before disconnecting or con-

necting hydraulic lines.

 Check hydraulic system components and all con-

nections and hoses for damage, leaks, and wear
before operating unit.

 Wear protective equipment such as safety

glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.

 Use a piece of paper or cardboard to search for leaks−−never use

bare hands. Do not use equipment if leaks are found.

 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics

near sparks or flames; do not smoke near hydraulic fluid.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting unit.

 If ANY fluid is injected into the skin, it must be surgically removed

within a few hours by a doctor familiar with this type of injury or gan­grene may result.

MOVING PARTS can injure.

 Keep away from moving parts such as fans,

belts and rotors.

 Keep all doors, panels, covers, and guards

closed and securely in place.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Before working on hydraulic system, turn off and lockout/tagout

unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.

 Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

HOT PARTS AND FLUID can burn.

 Do not touch hot parts bare handed or allow hot

fluid to contact skin.

 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

 Use only genuine replacement parts from the manufacturer.
 Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

1-5. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can
injure or kill.

 Incorrect installation or operation of this unit

could result in equipment failure and personal
injury. Only qualified persons should install, op­erate, and service this unit according to its
Owner’s Manual, industry standards, and na­tional, state, and local codes.

 Do not exceed the rated output or capacity of the compressor or

any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or prop­erty at risk.

 Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.

OM-248 551 Page 4

 Do not work on compressed air system with unit running unless

you are a qualified person and following the manufacturer’s in­structions.

 Do not modify or alter compressor or manufacturer-supplied

equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.

 Use only components and accessories approved by the manufac-

turer.

 Keep away from potential pinch points or crush points created by

equipment connected to the compressed air system.

 Do not work under or around any equipment that is supported only

by air pressure. Properly support equipment by mechanical
means.

HOT METAL from air arc cutting and
gouging can cause fire or explosion.

 Do not cut or gouge near flammables.
 Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can injure or kill.

 Before working on compressed air system,

turn off and lockout/tagout unit, release pres­sure, and be sure air pressure cannot be acci­dentally applied.

 Relieve pressure before disconnecting or con-

necting air lines.

 Check compressed air system components

and all connections and hoses for damage,
leaks, and wear before operating unit.

 Do not direct air stream toward self or others.
 Wear protective equipment such as safety glasses, hearing pro-

tection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.

 Use soapy water or an ultrasonic detector to search for

leaks−−never use bare hands. Do not use equipment if leaks are
found.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting unit.

 If ANY air is injected into the skin or body seek medical help im-

mediately.

MOVING PARTS can injure.

 Keep away from moving parts such as fans,

belts and rotors.

 Keep all doors, panels, covers, and guards

closed and securely in place.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.

 Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

HOT PARTS can burn.

 Do not touch hot compressor or air system

parts.

 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

BREATHING COMPRESSED AIR can in­jure or kill.

 Do not use compressed air for breathing.
 Use only for cutting, gouging, and tools.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.

 Release air pressure from tools and system be-

fore servicing, adding or changing attach­ments, or opening compressor oil drain or oil fill
cap.

 Use only genuine replacement parts from the manufacturer.
 Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

1-6. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

 Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

 Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

 Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

FLYING SPARKS can injure.

 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

MOVING PARTS can injure.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

OM-248 551 Page 5

WELDING WIRE can injure.

H.F. RADIATION can cause interference.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can injure.

 Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

 Use only genuine replacement parts from the manufacturer.
 Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

 If notified by the FCC about interference, stop using the

equipment at once.

 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as micro­processors, computers, and computer-driven
equipment such as robots.

 Be sure all equipment in the welding area is

electromagnetically compatible.

 To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

 If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-7. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

OM-248 551 Page 6

1-8. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: [phone], website:
www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

1-9. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may inter­fere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assess­ment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
For Standards about hydraulic systems, contact the National Fluid

Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: [phone],
website: www.nfpa.com).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-248 551 Page 7

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

fre_rom_2010−03

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

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

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

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-8. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures gra­ves. L’électrode et le circuit de soudage sont sous
tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage
semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont
sous tension. Des matériels mal installés ou mal mis
à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.
 Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

 Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

 Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé­talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste

OM-248 551 Page 8

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra­vailler seul!

 Couper l’alimentation ou arrêter le moteur avant de procéder à

l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformé-

ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation − Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau­des.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électro­cution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

 Ne pas enrouler les câbles autour du corps.
 Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.

 Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.
 Maintenir solidement en place tous les panneaux et capots.
 Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.

 Couper l’alimentation du poste et décharger les condensateurs

d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

 Ne pas toucher à mains nues les parties chau-

des.

 Prévoir une période de refroidissement avant

de travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.

 Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peu­vent être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.

 Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

 Fermer l’alimentation du gaz protecteur en cas

de non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir

d’un respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut

provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.

 Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

 Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

 Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor­mes de sécurité).

 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

 Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

 En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut
affecter l’ouïe.

 Porter des protections approuvés pour les

oreilles si le niveau sonore est trop élevé.

OM-248 551 Page 9

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)

 Placer les bouteilles debout en les fixant dans un support station-

peuvent affecter les implants médicaux.

 Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

 Les porteurs d’implants médicaux doivent consulter leur

médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Si une bouteille est endomma­gée, elle peut exploser. Du fait que les bouteilles de gaz font
normalement partie du procédé de soudage, les manipuler avec
précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

 Tenir les bouteilles éloignées des circuits de soudage ou autres

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

 Maintenir le chapeau de protection sur la soupape, sauf en cas

 Utiliser les équipements corrects, les bonnes procédures et suffi-

 Lire et suivre les instructions sur les bouteilles de gaz comprimé,

2-3. Dangers existant en relation avec le moteur

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

circuits électriques.

une bouteille.

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

bouteille.

d’utilisation ou de branchement de la bouteille.

samment de personnes pour soulever et déplacer les bouteilles.

l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu­rité.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

 Toujours porter une protection faciale, des

gants en caoutchouc et vêtements de protec­tion lors d’une intervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher des câbles

de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.

 Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

 Ne pas utiliser l’appareil de soudage pour charger des batteries ou

faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.

 Observer la polarité correcte (+ et −) sur les batteries.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

 Les sources d’étincelles, flammes nues, cigarettes et autres

sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.

 Respecter les consignes du fabricant de la batterie pour

travailler sur une batterie ou à proximité.

Le COURANT DE CHARGE DE BATTERIE peut
provoquer des blessures

batterie n’est pas disponible sur tous les modèles).

 Les opérations de charge de batterie ne doivent être effectuées

que par des personnes qualifiées.

 Ne charger que des batteries plomb−acide. Ne pas utiliser le

chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.

 Ne pas charger une batterie gelée.
 Ne pas utiliser de câbles de charge endommagés.
 Ne pas charger une batterie dont les bornes sont desserrées ou

présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.

 Avant de charger une batterie, sélectionner la tension de charge

correspondant à la tension de la batterie.

 Régler les commandes de charge de batterie sur la position d’arrêt

avant de brancher la batterie. Veiller à ce que les pinces de charge
ne se touchent pas.

OM-248 551 Page 10

(la fonctionnalité de charge de

 Ranger les câbles de charge à distance du capot, des portes et

des pièces mobiles du véhicule.

LE CARBURANT MOTEUR peut pro­voquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de

carburant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une source d’étincel-

les ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace

pour son expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout

carburant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

Les PIÈCES MOBILES peuvent causer
des blessures.

 S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

 Maintenir fermés et verrouillés les portes, panneaux,

recouvrements et dispositifs de protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.
 Lorsque cela est nécessaire pour des travaux d entretien et de

dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

 Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien, débrancher le câble négatif (−) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

 Remettre en place les portes, panneaux, recouvrements ou

dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la

mise en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une

intervention sur le générateur.

LES ÉTINCELLES À L’ÉCHAPPEMENT

s

e

­r

peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

 Ne pas toucher des parties chaudes à main

nues.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

 Il est préférable de vérifier le liquide de refroi-

dissement une fois le moteur refroidi pour éviter
de se brûler.

 Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré­cisé autrement dans la section maintenance du manuel du
moteur).

 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

 Mettre des lunettes de sécurité et des gants, placer un torchon sur

le bouchon du radiateur.

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi­ble et inodore.

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

L’ACIDE DE LA BATTERIE peut pro­voquer des brûlures dans les YEUX et
sur la PEAU.

 Ne pas renverser la batterie.
 Remplacer une batterie endommagée.

 Rincer immédiatement les yeux et la peau à l’eau.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

 Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces inflammables.

 Tenir à distance les produits inflammables de l’échappement.

2-4. Dangers liés à l’hydraulique

Les ÉQUIPEMENTS HYDRAULIQUES
peuvent provoquer des blessures ou
même la mort.

 Une installation ou une utilisation incorrecte

de cet appareil pourrait conduire à des dégâts
matériels ou corporels. Seul un personnel
qualifié est autorisé à installer, faire fonctionner
et réparer cet appareil conformément à son
manuel d’utilisation, aux normes industrielles
et aux codes nationaux, d’état ou locaux.

 Ne pas dépasser le débit nominal ou la capacité de la pompe

hydraulique ou de tout équipement du circuit hydraulique.
Concevoir le circuit hydraulique de telle sorte que la défaillance
d’un composant hydraulique ne risque pas de provoquer
un accident matériel ou corporel.

 Avant d’intervenir sur le circuit hydraulique, couper l’alimentation

électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.

 Ne pas intervenir sur le circuit hydraulique lorsque l’appareil

fonctionne. Seul un personnel qualifié et appliquant les consignes
du fabricant est autorisé le faire.

 Ne pas modifier ou altérer la pompe hydraulique ou

les équipements fournis par le fabricant. Ne pas débrancher,
désactiver ou neutraliser les équipements de sécurité du circuit
hydraulique.

 Utiliser uniquement des composants et accessoires homologués

par le fabricant.

 Se tenir à l’écart de tout point présentant un danger de pincement

ou d’écrasement créé par l’équipement raccordé au circuit
hydraulique.

 Ne pas intervenir sous ou autour d’un équipement qui n’est

soutenu que par la pression hydraulique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.

Le LIQUIDE HYDRAULIQUE risque de
provoquer des blessures ou même la mort.

 Avant d’intervenir sur le circuit hydraulique,

couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut
être remis sous pression par inadvertance.

 Détendre la pression avant de débrancher ou

de brancher des canalisations hydrauliques.

 Avant d’utiliser l’appareil, contrôler

les composants du circuit hydraulique,
les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure.

 Pour intervenir sur un circuit hydraulique, porter un équipement

de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.

 Pour rechercher des fuites, utiliser un morceau de papier ou

de carton, jamais les mains nues. En cas de détection de fuite,
ne pas utiliser l’équipement.

 Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas

intervenir sur des composants hydrauliques à proximité
d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.

 Remettre les portes, panneaux, recouvrements ou dispositifs

de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.

 En cas de pénétration d’un QUELCONQUE liquide dans la peau,

celui−ci doit être retiré chirurgicalement sous quelques heures par

OM-248 551 Page 11

un médecin familiarisé avec ce type de blessure, faute de quoi
la gangrène pourrait apparaître.

Les PIÈCES MOBILES peuvent causer

des blessures.

 S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

 Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs
de protection.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

 Avant d’intervenir sur le circuit hydraulique, couper l’alimentation

électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.

 Demander seulement à un personnel qualifié d’enlever

les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.

 Remettre en place les portes, panneaux, recouvrements ou

dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.

2-5. Dangers liés à l’air comprimé

LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.

 Ne pas toucher les pièces chaudes à main nue

ni laisser des liquides chauds entrer en contact
avec la peau.

 Prévoir une période de refroidissement avant d’intervenir

sur l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils

recommandés et porter des gants de soudage et des vêtements
épais pour éviter les brûlures.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

 Effectuer l’entretien en respectant les manuels d’utilisation,

les normes industrielles et les codes nationaux, d’état et locaux.

Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.

 Une installation ou une utilisation incorrecte de

cet appareil pourrait conduire à des dégâts
matériels ou corporels. Seul un personnel
qualifié est autorisé à installer, utiliser et
entretenir cet appareil conformément à son
manuel d’utilisation, aux normes industrielles et
aux codes nationaux, d’état ou locaux.

 Ne pas dépasser le débit nominal ou la capacité du compresseur

ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident
matériel ou corporel.

 Avant d’intervenir sur le circuit d’air comprimé, couper

l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.

 Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil

fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.

 Ne pas modifier ou altérer le compresseur ou les équipements

fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air
comprimé.

 Utiliser uniquement des composants et accessoires

homologués par le fabricant.

 Se tenir à l’écart de tout point présentant un danger de pincement

ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.

 Ne pas intervenir sous ou autour d’un équipement qui n’est

soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.

L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.

 Avant d’intervenir sur le circuit d’air comprimé,

couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.

 Détendre la pression avant de débrancher ou

de brancher des canalisations d’air.

 Avant d’utiliser l’appareil, contrôler

les composants du circuit d’air comprimé,
les branchements et les flexibles en
recherchant tout signe de détérioration, de fuite
et d’usure.

 Ne pas diriger un jet d’air vers soi−même ou vers autrui.

 Pour intervenir sur un circuit d’air comprimé, porter un équipement

de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.

 Pour rechercher des fuites, utiliser de l’eau savonneuse ou

un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.

 Remettre les portes, panneaux, recouvrements ou dispositifs

de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.

 En cas d’injection d’air dans la peau ou le corps, demander

immédiatement une assistance médicale.

MÉTAL CHAUD provenant du décou-

page ou du gougeage à l’arc risque de

provoquer un incendie ou une explo-

sion.

 Ne pas découper ou gouger à proximité de

produits inflammables.

 Attention aux risques d’incendie: tenir un extincteur à proximité.

OM-248 551 Page 12

L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.

 Ne pas inhaler d’air comprimé.
 Utiliser l’air comprimé uniquement pour

découper ou gouger ainsi que pour l’outillage
pneumatique.

Une PRESSION D’AIR RÉSIDUELLE

e

-

-

,

ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.

 Remettre en place les portes, panneaux, recouvrements ou

dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.

 Détendre la pression pneumatique des outils et

circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.

Les PIÈCES MOBILES peuvent causer
des blessures.

 S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

 Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs
de protection.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

 Avant d’intervenir sur le circuit d’air comprimé, couper

l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.

 Demander seulement à un personnel qualifié d’enlever

les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.

 Ne pas toucher aux pièces chaudes, utiliser les outils

recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

 Effectuer l’entretien en respectant les manuels d’utilisation,

les normes industrielles et les codes nationaux, d’état et locaux.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher de pièces chaudes

du compresseur ou du circuit d’air.

 Prévoir une période de refroidissement

avant d’intervenir sur l’équipement.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.

2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

 Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT

peut provoquer des blessures.

 Utiliser l’anneau de levage pour lever l’appareil

et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dé­passer le poids nominal maximal de l’œilleton
(voir les spécifications).

 Utiliser un équipement de levage de capacité suffisante pour

lever l’appareil.

 En utilisant des fourches de levage pour déplacer l’unité, s’assu-

rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.

 Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

 Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.

LE SURCHAUFFEMENT peut

endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

 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
quence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz

s’il y a lieu.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

 Porter un écran facial pour protéger le visage et

les yeux.

 Affûter l’électrode au tungstène uniquement à

la meuleuse dotée de protecteurs. Cette ma­nœuvre est à exécuter dans un endroit sûr lors­que l’on porte l’équipement homologué de pro­tection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

Les PIÈCES MOBILES peuvent
causer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

 Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga­geant le fil de soudage.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

OM-248 551 Page 13

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut

provoquer des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

 Effectuer l’entretien en respectant les manuels d’utilisation,

les normes industrielles et les codes nationaux, d’état et locaux.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe­ments de radio−navigation et de communica­tion, les services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

 L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

 L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec­tronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé­mentaires telles que le déplacement du poste, l’utilisation de câ­bles blindés, l’utilisation de filtres de ligne ou la pose de protec­teurs dans la zone de travail.

2-7. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu-

lation.

Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère

Pour les moteurs à essence :

Pour les moteurs diesel :

cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver

les mains après toute manipulation.

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

OM-248 551 Page 14

2-8. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: [phone], website:
www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

2-9. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
For Standards about hydraulic systems, contact the National Fluid

Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: [phone],
website: www.nfpa.com).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-248 551 Page 15

3-1. Symbol Definitions

 Complete Parts List available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

Read Operator’s

Manual

Seconds Time

A

Alternating Current

h

Engine Choke

Engine Oil Fuel Battery (Engine) Engine

Positive Negative

Hours

s

Circuit Protector Temperature

SECTION 4 − SPECIFICATIONS

4-1. 145 Models Weld, Power, And Engine Specifications

Welding

Mode

Weld

Output

Range

Rated

Welding Output

Maximum

Open Circuit

Voltage

Generator

Power Rating

Amperes

(AC)

V

Fuel

Capacity

Volts

Output

Protective Earth

(Ground)

Engine

Single-Phase,

4.5 kVA/kW (Peak)
4 kVA/kW

(Continuous)

34/17 A,

120/240 V AC,

60 Hz

CC/DC 40 − 145 A

145 A, 25 V,

20% Duty Cycle

100 A, 25 V,

60% Duty Cycle

80 A, 25 V

100% Duty Cycle

80

4-2. 185DX Model Weld, Power, And Engine Specifications

Welding

Mode

CC/DC 55 − 185 A

Weld

Output

Range

Rated

Welding Output

185 A, 25 V,

20% Duty Cycle

130 A, 25 V,

60% Duty Cycle

100 A, 25 V

100% Duty Cycle

Maximum

Open Circuit

Voltage

80

Generator

Power Rating

Single-Phase,

6 kVA/kW (Peak)

5.5 kVA/kW

(Continuous)

40/23 A,

120/240 V AC,

60 Hz

Standard Model:

1.8 gal (6.9 L)
Tank

DX Model:

5 gal (19 L)

Tank

Fuel

Capacity

5 gal (19 L)

Tank

Kohler CS10

Air-Cooled,

One-Cylinder,

Four-Cycle,
10 HP (300 CC),
Gasoline Engine

(Recoil Or Electric-

Start)

Engine

Kohler CS12.75

Air-Cooled,

One-Cylinder,

Four-Cycle,

12.75 HP (360 CC),
Gasoline Engine

(Electric-Start)

OM-248 551 Page 16

4-3. Dimensions, Weights, And Operating Angles

Dimensions

Height 22-3/4 in (578 mm)

Width 22-3/4 in (577 mm)

Depth 31-5/8 in (803 mm)

A 31-5/8 in (803 mm)
B 10-9/16 in (268 mm)
C 13-25/64 in (340 mm)
D 22-3/4 in (577 mm)
E 1-9/16 in (40 mm)
F 19-5/8 in (498 mm)
G 13/32 in (10 mm) Dia.

Weight

145 Standard Model: 263 lb (119 kg)

145DX Model: 309 lb (140 kg)
185DX Model: 315 lb (143 kg)

Optional Lifting Eye

Weight Rating

430 lb (195 kg)

B

A

C

E

D

F

Engine End

 Complete Parts List available at www.MillerWelds.com

! Do not exceed tilt angles or engine could

be damaged or unit could tip.

! Do not move or operate unit where it

could tip.

15°

15°

803 594

G

4

Holes

803 403

15°
15°

4-4. Duty Cycle

200
180
160
140

120
100

80

WELD AMPERES

60
40

20

0

0102030405060708090100

145 Models

1

Continuous Welding

185 Model

% DUTY CYCLE

1 100% Duty Cycle
Duty cycle is the percentage of 10

minutes that unit can weld at rated
load without overheating.

 The 145 Models are rated for

welding at 80 Amperes con­tinuously.

 The 185 Model is rated for

welding at 100 Amperes con­tinuously.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

220 625-A / 220 626−A

OM-248 551 Page 17

4-5. Volt-Ampere Curves

A. 145 Models

90
80

70

60

 Complete Parts List available at www.MillerWelds.com

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

50

40

VOLTS

30

20

10

0

0

B. 185DX Model

80

70

60

50

MID MAX

MIN

50 100 150 200 250

AMPERES

220 602

40

VOLTS

30

20

10

0

0

OM-248 551 Page 18

MIN

MAX

MID

50 100 150 200 250 300

AMPERES

220 605−A

4-6. Fuel Consumption

A. Fuel Consumption While Welding

1.00

0.80

0.60

US Gal./Hr.

0.40

185 Model Idle

0.20
145 Model Idle

0.00

0 25 50 75 100 125 150 175 200

DC WELD AMPERES AT RATED DUTY CYCLE

B. Fuel Consumption − Auxiliary Power 145 Models

145 Models

 Complete Parts List available at www.MillerWelds.com

185 Model

1.00

0.80

0.60

0.40

US Gal./Hr.

0.20
IDLE

0.00

0123456

AUXILIARY POWER KW AT 100% DUTY CYCLE

C. Fuel Consumption − Auxiliary Power 185DX Model

1.00

0.80

0.60

U.S. Gal./Hr.

0.40

0.20

0.00

Idle

01 2345678

Aux Power kW At 100% Duty Cycle

220 637 / 220 639-A

OM-248 551 Page 19

4-7. Generator Power Curve

A. Generator Power 145 Models

300

250

200

240 Volt

150

VOLTS

100

50

 Complete Parts List available at www.MillerWelds.com

The ac generator power curves
show the generator power available
in amperes at the receptacles.

120 Volt

0

0

10 20 30 40 50 60 70 80

B. Generator Power 185DX Model

300

250

200

150

VOLTS

100

AMPERES

220 581

240 VOLT

120 VOLT

50

0

01020304050607080

OM-248 551 Page 20

AMPERES

220 594−A

SECTION 5 − INSTALLATION

5

5-1. Installing Welding Generator

Movement Airflow Clearance

18 in.

(460 mm)

 Complete Parts List available at www.MillerWelds.com

18 in.

(460 mm)

18 in.

(460 mm)

Location

Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all
DOT and other applicable codes

18 in.

(460 mm)

Do not install unit where air
flow is restricted or engine
may overheat.

OR

Ref 151 556 / Ref. 800 652 / 803 594 / S-0854

18 in.

(460 mm)

-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

! Always ground generator frame to

vehicle frame to prevent electric
shock and static electricity hazards.

! Also see AWS Safety & Health Fact

Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Gen­erators.

! Bed liners, shipping skids, and

3

some running gear insulate the
welding generator from the vehicle
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.

! If unit does not have GFCI recep-

tacles, use GFCI-protected exten­sion cord.

rot_grnd2 2010−04 − 800 652-D

1 Equipment Grounding Terminal (On

Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground

terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.

 Electrically bond generator frame to ve-

hicle frame by metal-to-metal contact.

OM-248 551 Page 21

 Complete Parts List available at www.MillerWelds.com

5-3. Grounding Generator When Supplying Building Systems

2

5-4. Fuel Valve Positions

GND/PE

1 2

! Ground generator to sys-

tem earth ground if supply­ing power to a premises
(home, shop, farm) wiring
system.

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #8 AWG or larger insulated

copper wire.

 Use ground device as stated

3

1

in electrical codes.

3 Ground Device

800 576-B

1 Fuel Valve Open Position
2 Fuel Valve Closed Positions

 Always close fuel valve after

stopping unit. Moving unit
with fuel valve open may
cause carburetor flooding
and make starting difficult.

OM-248 551 Page 22

2

Ref. 804 971-C

5-5. Engine Prestart Checks

1

1/2 in

(13 mm)

Gasoline

Full

 Complete Parts List available at www.MillerWelds.com

Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.

1 Fuel Valve
Open valve.

 Close fuel valve before moving

unit or carburetor may flood
and make starting difficult.

Fuel

Add fresh fuel before starting
engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
fuel level on a cold engine before
use each day.

Oil

After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see en­gine manual).

Unit stops if oil level is too low. Unit
cannot be restarted until sufficient
oil is added.

 To improve cold weather

starting:

Keep battery in good condition.
Store battery in warm area off
concrete surface.

Use correct grade oil for cold
weather.

1

Full

Filler Neck

Bring Level Up To
Point Of Overflow

Low

803 594 / 803 595 / 803 596 / 248 493

OM-248 551 Page 23

5-6. Connecting The Battery (As Applicable)

 Complete Parts List available at www.MillerWelds.com

! Turn Engine Switch to Off.
! Connect negative (−)

cable last.

Tools Needed:

1/2 in

5-7. Weld Output Terminals

1

Tools Needed:

3/4 in

+

−

803 595-B / 803 466

1 Negative (−) Weld Output

Terminal

2 Positive (+) Weld Output

Terminal

For Direct Current Electrode Posi­tive (DCEP), connect work cable to

2

Negative (−) terminal and electrode
holder to Positive (+) terminal.

For Direct Current Electrode nega­tive (DCEN), reverse cable con­nections.

OM-248 551 Page 24

803 596−B

5-8. Connecting To Weld Output Terminals

1

6

3

4

5

Tools Needed:

2

3/4 in.

 Complete Parts List available at www.MillerWelds.com

! Stop engine.
! Failure to properly connect

weld cables may cause ex­cessive heat and start a fire,
or damage your machine.

 Do not place anything between

weld cable terminal and copper
bar. Make sure that the sur­faces of the weld cable terminal
and copper bar are clean.

1 Correct Weld Cable

Connection

2 Incorrect Weld Cable

Connection
3 Weld Output Terminal
4 Supplied Weld Output

Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld

output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop­per bar.

803 778-B

5-9. Selecting Weld Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

Weld Output

Terminals

! Turn off power before

connecting to weld out­put terminals.

100 ft (30 m) or Less

10 −

Welding

Amperes

60%

Duty

Cycle

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)

60 − 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 − 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

* 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, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

Ref. S-0007-G 2009−08

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

OM-248 551 Page 25

 Complete Parts List available at www.MillerWelds.com

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Engine Controls

1

3

1 Engine Switch
Use switch to control ignition circuit. Turn

switch to Start position for electric start. Turn
switch to On position to start engine using
starter handle (recoil). Turn switch to Off posi­tion to stop engine.

2 Low Oil Level Light
Light goes on and engine stops if engine oil

level is too low.
Engine cannot be restarted until sufficient oil

is added.

 Component location may vary

by model. DX Model shown.

! Stop engine and add oil if light goes on

(see Section 5-5).

3 Starter Handle
Use starter handle to start unit if electric start

does not work.

4

4 Choke Control

Use control to change engine air/fuel mix.
Move control to far right if starting a cold en­gine. Move control to far left if starting a warm
engine.

The engine starts at weld/power speed and
runs at weld/power speed under weld or gen­erator power load. For the DX models (with
Run/Idle selected) : the engine returns to idle
speed 12 seconds after start-up or after weld
or generator power load is removed.

To Start:

 Open fuel valve (see Section 5-5).
 Set choke.

2

 Electric-Start: Turn Engine switch to

Start position.
Recoil: Turn Engine switch to On posi­tion. Pull starter handle until engine
starts.

 Open choke as engine warms.

! If the engine does not start, let engine

come to a complete stop before at­tempting restart.

To Stop:

 Turn Engine switch to Off.

 Always close fuel valve after stopping

unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.

803 595

OM-248 551 Page 26

6-2. Front Panel Controls

 Complete Parts List available at www.MillerWelds.com

2

1

1 Welding Range Table
Use table to determine correct weld amper-

age based on electrode size, type, and mate­rial thickness.

2 Run / Idle Switch (DX Models Only)
Use switch to select whether the engine stays

at run speed continuously or whether the auto
idle feature is enabled so engine speed re­turns to idle speed after start−up or after weld
or generator load is removed.

4

3 Weld Output Control

 Set control at maximum for full generator

power output at AC receptacles.

Use control to select weld amperage. Control
may be adjusted while welding.

To Set Weld Output Control: Use table to
determine correct size electrode for weld am­perage. Select electrode type and set control
to corresponding amperage range on name-

3

218 610

plate. Adjust control to obtain desired weld
performance.

EXAMPLE:
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
4 Hour Meter (DX Models Only)
Use hour meter to help schedule routine main-

tenance.

OM-248 551 Page 27

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Panel Receptacles

 Complete Parts List available at www.MillerWelds.com

124 35

 Generator power decreases as weld

current increases. Set Weld Output
control to maximum for full generator
power output at AC receptacles.

1 240 V AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at

weld/power speed.
2 120 V 20 A AC Duplex Receptacle

RC2

3 120 V 20 A AC Duplex Receptacle

RC3

RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.

NOTICE − Do not parallel the two 120V du-
plex receptacles.

6

145 Models

4.5 kVa/kW Peak
4 kVa/kW Continuous
34/17 Amperes
120/240 Volts AC
60 Hz

4 Supplementary Protector CB1

CB1 protects the receptacles from over­load. If CB1 opens, the receptacles do not
work. Move switch to the On position to re­set.

5 Supplementary Protectors CB2, CB3

(185DX Models Only)

CB2 protects RC2 and CB3 protects RC3
from overload. If the supplementary pro­tector opens, the receptacle does not
work. Press button to reset.

 If supplementary protector continues

to open, contact Factory Authorized
Service Agent.

Combined output of all receptacles limited
to the continuous rating of the generator

185 Model

6 kVa/kW Peak

5.5 kVa/kW Continuous
40/23 Amperes
120/240 Volts AC
60 Hz

218 611−B

(See Section 12 − Generator Power
Guidelines).

6 Optional 120 V 20 A AC GFCI Re-

ceptacles GFCI-2 and GFCI-3

GFCI2 and GFCI3 supply 60 Hz single­phase power at weld/power speed. Maxi­mum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit protection is the same as
standard receptacles.

If a ground fault is detected, the GFCI Re­set button pops out and the circuit opens
to disconnect the faulty equipment. Check
for damaged tools, cords, plugs, etc. con­nected to the receptacle. Press button to
reset receptacle and resume operation.

 At least once a month, run engine at

weld/power speed and press Test but­ton to verify GFCI is working properly.

OM-248 551 Page 28

 Complete Parts List available at www.MillerWelds.com

SECTION 8 − MAINTENANCE

 Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

8-1. Routine Maintenance

! Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

25

Hours

Every

50

Hours

Every

100

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Fuel Level  Oil Level  Oil, Fuel Spills

 Air Cleaner Precleaner

 Weld Terminals

 Oil  Air Cleaner Element  Cooling System  Spark Plug Gap

0.030 in.

Reference

Section 8-3,
5-5

Section 8-3

Engine
Manual,
Section 8-2,
8-3, 8-4

Every

200

Hours

Every

300

Hours

Every

500

Hours

 Battery Terminals (DX
Models)

 Unreadable Labels

Valve Clearance*

 Weld Cables  Slip Rings*

 Spark Arrestor Screen

(Optional on DX Models)

 Brushes*

 Fuel Filter

Engine
Manual

Engine
Manual

OM-248 551 Page 29

8-2. Maintenance Label

 Complete Parts List available at www.MillerWelds.com

OM-248 551 Page 30

8-3. Servicing Air Cleaner

145 Standard Model

 Complete Parts List available at www.MillerWelds.com

! Stop engine.

NOTICE − Do not run engine with-
out air cleaner or with dirty element.

1 Precleaner
2 Paper Element

1

3 Foam Element

 Do not wash paper element or

clean with compressed air.

Remove cover.

2

Wash precleaner or foam element
with soap and water solution. Allow
to air dry completely.

Dip precleaner or foam element in
clean engine oil. Squeeze out ex­cess oil. The engine will smoke if
too much oil remains.

Replace paper element if dirty, oily,
or damaged.

DX Models

8-4. Changing Fuel Filter (DX Models Only)

Tools Needed:

3

805 055 / Kohler TP−2503B

! Stop engine, close fuel valve,

and let cool.

! After servicing, start engine

and check for fuel leaks.

Stop engine, close fuel valve,

tighten connections as ne-

cessary, and wipe up spilled

fuel.

1 Fuel Filter
Locate fuel filter below fuel tank.

Release hose clamps and remove

1

filter. Replace filter . Ensure flow ar­row points towards carburetor.

804 081-B

OM-248 551 Page 31

8-5. Changing Oil

2

1

 Complete Parts List available at www.MillerWelds.com

 Change oil while engine is

warm. Make sure engine is

level when filling, checking,

and changing the oil.

1 Oil Drain Plug
2 Oil Fill/Check Plug
Remove the oil drain plug and oil fill/

2

1

check plug. Be sure to allow ample
time for oil to drain completely.

Reinstall drain plug and tighten to
13 ft/lb (17.6 N⋅m).

Fill crankcase according to main­tenance label in Section 8-2.

Reinstall oil fill/check plug.

Tools Needed:

8-6. Adjusting Engine Speed (145 Standard Model)

3675 − 3750 RPM
(61.25 − 62.5 Hz)

Kohler TP−2503B

After tuning engine, check engine
speed. See table for proper no load
speed. If necessary, adjust speed
as follows:

Start engine and run until warm.
1 Adjustment Screw
To increase speed, turn screw in

(clockwise). To decrease speed,
turn screw out (counterclockwise).

! Stop engine. Close fuel

valve.

1

Tools Needed:

OM-248 551 Page 32

803 594

8-7. Adjusting Engine Speed (DX Models)

 Complete Parts List available at www.MillerWelds.com

After tuning engine, check engine
speed. See table for proper no load
speed. If necessary, adjust speed

2450 − 2550 RPM
(40.83 − 42.5 Hz)

3675 − 3750 RPM
(61.25 − 62.5 Hz)

as follows:
Start engine and run until warm.
Set Weld Output Control to Max.

Weld/Power Speed Adjustment

1 Adjustment Screw
To increase speed, turn screw in

(clockwise). To decrease speed,
turn screw out (counterclockwise).

Idle Speed Adjustment

2 Throttle Solenoid TS1
3 Adjustment Screw
Loosen two screws on side of

throttle solenoid TS1. Adjust TS1
until idle speed is approximately
2500 rpm. Use adjustment screw
to fine tune idle speed. Be sure TS1
plunger bottoms at idle. Tighten two
screws on TS1.

! Stop engine. Close fuel

valve.

1

3

2

Tools Needed:

803 595

OM-248 551 Page 33

SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output or generator power out­put at ac receptacles.

No weld output; generator power out­put okay at ac receptacles.

Low weld output. Check Weld Output control setting.

High weld output. Check Weld Output control setting.

Erratic weld output. Check Weld Output control setting.

Be sure all equipment is disconnected from receptacles when starting unit.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.

Check Weld Output control setting.

Check weld connections.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier

SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z.

Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).
Service engine air cleaner (see Section 8-3). Service engine fuel filter (see Section 8-4).
Check weld cable size and length.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier

SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z.

Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).

Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).
Check throttle/governor linkage for smooth, non-binding operation.
Service engine air cleaner (see Section 8-3). Service engine fuel filter (see Section 8-4).

 Complete Parts List available at www.MillerWelds.com

B. Generator Power

Trouble Remedy

No output at generator power ac re­ceptacles; no weld output.

No output at generator power ac re­ceptacles; weld output okay.

High output at generator power ac
receptacles.

OM-248 551 Page 34

Be sure all equipment is disconnected from receptacles when starting unit.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.

Reset and check supplementary protector (see Section 7-1).

Check receptacle wiring and connections.
Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.
Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).

 Complete Parts List available at www.MillerWelds.com

Trouble Remedy

Low output at generator power ac
receptacles.

Erratic output at generator power ac
receptacles.

C. Engine

Trouble Remedy

Engine will not crank. Check and replace ignition fuse (see engine manual).

Check Weld Output control setting.

Check engine speed, and adjust if necessary (see Section 8-6 or 8-7). Open circuit voltage is reduced
as engine speed drops.

Check fuel level.
Have Factory Authorized Service Agent check connections at terminal block 1T.
Check receptacle supplementary protector, wiring, and connections.
Check throttle linkage for smooth, non-binding operation.
Service air cleaner according to engine manual. Service engine fuel filter (see Section 8-4).
Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start. Check fuel level (see Section 5-5).

Move choke control to correct position (see Section 6-1).

Open fuel valve (see Section 5-5). Close fuel valve before moving unit or carburetor may flood and make
starting difficult.

Check battery voltage.

Check battery connections and tighten if necessary.

Check oil level (see Section 5-5). Engine stops if oil level is too low. Refill crankcase with proper viscosity
oil for operating temperature.

Have Factory Authorized Service Agent check low oil level shutdown switch.

Engine stopped during normal
operation.

Battery discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 8-6 or 8-7).

Check fuel level (see Section 5-5).

Open fuel valve (see Section 5-5). Close fuel valve before moving unit or carburetor may flood and make
starting difficult.

Check oil level (see Section 5-5). Engine stops if oil level is too low.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check engine battery charging circuit and connections according to engine manual.

Check throttle/governor linkage for smooth, non-binding operation.

Tune-up engine according to engine manual.

OM-248 551 Page 35

SECTION 10 − PARTS LIST

10-1. Recommended Spare Parts

Part

No.

Recommended Spare Parts

221581 Tune−up & Filter Kit, Kohler CS 10 Recoil (includes) ................... .. ...................

203960 Spark Plug, 1................... .... ....................................................

221579 Filter, Air Kohler CS 10 Recoil 1................... .... ....................................

221580 Filter, Air Pre Cleaner Kohler CS 10 Recoil 1................... .... .........................

221584 Tune−up & Filter Kit, Kohler CS 10 & 12 Electric (includes)................... .. ..............

203960 Spark Plug, 1................... .... ....................................................

221582 Filter, Air Kohler CS 10 & 12 Electric 1................... .... ..............................

221583 Filter, Air Pre Cleaner Kohler CS 10 & 12 Electric 1................... .... ...................

247590 Filter, Fuel 1................... .. .......................................................

239348 Fuse, 10 Amp Ato Type 1................... .. ...........................................

Description

 Complete Parts List available at www.MillerWelds.com

Quantity

OM-248 551 Page 36

Notes

 Complete Parts List available at www.MillerWelds.com

WELD JOINT

TYPES

GROOVE

FILLET

Ref. AWS/ANSI D1.1

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

BUTT

1G

T−JOINT

1F

BUTT

2G

T−JOINT

2F

BUTT

3G

T−JOINT

3F

T−JOINT

4F

OM-248 551 Page 37

BUTT

4G

Ref. 804 248-A

SECTION 11 − ELECTRICAL DIAGRAMS

OM-248 551 Page 38

226 737-A

Figure 11-1. Circuit Diagram For 145 Standard Model

Figure 11-2. Circuit Diagram for DX Models

226 738-A

OM-248 551 Page 39

SECTION 12 − GENERATOR POWER GUIDELINES

 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

12-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

1

2

3

OR

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

gen_pwr 2010−04 − ST-800 577

12-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

frame to vehicle frame to pre­vent electric shock and static
electricity hazards.

! Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #8 AWG or larger insu­lated copper wire.

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

OM-248 551 Page 40

800 652-D

12-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #8 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

12-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115

4.5

AMPS

60

Hz

ST-800 576-B

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 running
(see Section 12-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run­ning power requirement in watts.

4.5 A x 115 V = 520 W
The load applied by the drill is 520

watts.
Example 2: If three 200 watt flood

lamps are used with the drill from Ex­ample 1, add the individual loads to
calculate total load.

(3 x 200W) + 520 W = 1120 W
The total load applied by the three

flood lamps and drill is 1120 watts.

S-0623

OM-248 551 Page 41

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 10550 2850
3 HP 15900 3900
5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

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 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700
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
2 gal/min 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-248 551 Page 42

12-7. Approximate Power Requirements For Contractor Equipment

Contractor 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 10500 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-248 551 Page 43

12-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage
3 Motor HP

4
1
3

VOLTS AMPS
CODE 60
HP

AC MOTOR
230 2.5
M
1/4

Hz
PHASE

1

2

4 Motor Voltage
To find starting amperage:
Step 1: Find code and use table to

find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.

Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-

age (see example).
Welding generator amperage out-

put must be at least twice the
motor’s running amperage.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper­age required for a 230 V, 1/4 HP mo­tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2

amperes.

S-0624

12-9. How Much Power Can Generator Supply?

1

2

OM-248 551 Page 44

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)
loads in order from largest to small­est, and add resistive loads last.

2 5 Second Rule
If motor does not start within 5

seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.

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

12-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.

! Properly install and ground

this equipment according to
its Owner’s Manual and na­tional, state, and local codes.

 Customer-supplied equipment

is required if generator will sup­ply standby power during
emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load

from electric utility service to the
generator. Transfer load back to
electric utility when service is re­stored.

Install correct switch (customer­supplied). 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 Welding 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 volt­age and frequency.

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 12-4).

OM-248 551 Page 45

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(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

Load (Watts) 4 6 8 10 12 14

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(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-248 551 Page 46

Load (Watts) 4 6 8 10 12 14

SECTION 13 − STICK WELDING (SMAW) GUIDELINES

13-1. Stick Welding Procedure

! Weld current starts when

electrode touches work-

Tools Needed:

Equipment Needed:

Constant Current

Welding Power Source

5

4

2

3

piece.

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.

 Always wear appropriate per-

sonal protective clothing.

1 Workpiece
Make sure workpiece is clean be-

fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode re-

quires less current than a large
one. Follow electrode manufactur­er’s instructions when setting weld
amperage (see Section 13-2).

4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.

7 Slag
Use a chipping hammer and wire

brush to remove slag. Remove
slag and check weld bead before
making another weld pass.

6

1

7

stick 2010−02 − 151 593

OM-248 551 Page 47

13-2. Electrode and Amperage Selection Chart

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT
HORIZ
FILLET

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

LOW HYDROGEN,

MED

LOW

LOW
LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087 985-A

13-3. Striking an Arc

1 Electrode
2 Workpiece
3 Arc

Scratch Technique

1

Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out, electrode was lifted too
high. If electrode sticks to work-

2

piece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down to

3

1

workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free
it.

2

3

S-0049 / S-0050

OM-248 551 Page 48

13-4. Positioning Electrode Holder

1

1 End View Of Work Angle

2 Side View Of Electrode Angle

10°-30°

90° 90°

Groove Welds

1

45°

45°

Fillet Welds

13-5. Poor Weld Bead Characteristics

10°-30°

2

2

2

S-0060

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

4

3

1

13-6. Good Weld Bead Characteristics

1

5

S-0053-A

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding

Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in met­als being welded.

5234

4 No Overlap
5 Good Penetration into Base

Metal

S-0052-B

OM-248 551 Page 49

13-7. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Small

Electrode Angle

Arc Length

Too Short

Travel Speed

Slow

10° - 30°

Drag

Normal Too Long

Normal Fast

 Weld bead shape is affected

by electrode angle, arc
length, travel speed, and thick­ness of base metal.

Angle Too Large

Spatter

S-0061

13-8. Electrode Movement During Welding

1

3

 Normally, a single stringer

bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple

2

stringer beads work better.

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side to Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a

wide area in one pass of the elec­trode. Do not let weave width ex­ceed 2-1/2 times diameter of
electrode.

S-0054-A

OM-248 551 Page 50

13-9. Groove (Butt) Joints

1

3

1/16 in.

(1.6 mm)

30°

1 Tack Welds
Prevent edges of joint from draw-

ing together ahead of electrode by
tack welding the materials in posi­tion before final weld.

2

4

2 Square Groove Weld
Good for materials up to 3/16 in. (5

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in.

(5-19 mm) thick. Cut bevel with
oxyacetylene or plasma cutting
equipment. Remove scale from
material after cutting. A grinder can
also be used to prepare bevels.

Create 30 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than

3/16 in. (5 mm).

S-0062

13-10. Lap Joint

2

13-11. Tee Joint

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.

30°
Or Less

1

3

1

45°

Or

2

Less

2

30°
Or Less

1

3

3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

er fillet is needed. Remove slag be­fore making another weld pass.
Weld both sides of joint for maxi­mum strength.

1 Electrode
2 Fillet Weld
Keep arc short and move at defi-

nite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both
sides of upright section.

1

3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section
13-8. Remove slag before making
another weld pass.

S-0063 / S-0064

S-0060 / S-0058-A / S-0061

OM-248 551 Page 51

13-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

13-13. Troubleshooting

1 Vise
2 Weld Joint
3 Hammer
Strike weld joint in direction shown.

A good weld bends over but does
not break.

3

2 To 3 in.

(51-76 mm)

2
1

Porosity − small cavities or holes resulting from gas pockets in weld metal.

2

1

S-0057-B

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

welding.

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding

weld bead.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

OM-248 551 Page 52

welding.

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Good Penetration

Reduce travel speed.

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Good Penetration

Increase and/or maintain steady travel speed.

Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-248 551 Page 53

Notes

Ref. AWS/ANSI D1.1

WELD JOINT

TYPES

FILLETGROOVE

WELD POSITION:

FLAT

BUTT

1G

T−JOINT

1F

HORIZONTAL

BUTT

2G

T−JOINT

2F

BUTT

OVERHEAD

T−JOINT

4F

VERTICAL

3G

T−JOINT

3F

Ref. 804 248-A

BUTT

4G

OM-248 551 Page 54

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

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you ...

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need. Most replacement
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Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2010

(Equipment with a serial number preface of MA or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
original retail purchaser that new Miller equipment sold after the
effective date of this limited warranty is free of defects in material
and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.

1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules

2. 3 Years — Parts and Labor
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter

Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)

3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

guarantees or warranties expressed or implied.

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4) payment
of or credit for the purchase price (less reasonable depreciation
based upon actual use) upon return of the goods at customer’s risk
and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of any
kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2010−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010−01

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.