Miller FUSION 185 Owners manual

OM-284208C

Processes

Stick (SMAW) Welding

Description

Engine Driven Welder/Generator

Fusion 185

2023-05

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

OWNER’S MANUAL

From Miller to You

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

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

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

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the
worksite. We’ve made installation and operation quick and easy. With
Miller, you can count on years of reliable service with proper
maintenance. And if for some reason the unit needs repair, there’s a
Troubleshooting section that will help you figure out what the problem
is, and our extensive service network is there to help fix the problem.

Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Warranty and maintenance information for your particular model are
also provided.

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

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

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

TABLE OF CONTENTS

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

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3 Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

1-5 Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

1-7 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-8 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-3 Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-4 Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-5 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . 11

2-6 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-7 Principales normes de sécurité. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-8 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-2 Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-2 Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-3 Information About Default Weld Parameters And Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-4 Weld, Power, And Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-5 Unit Specifications For Utility Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-6 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-7 Dimensions, Weights, And Operating Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-8 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-9 Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-10 Generator Power Curve . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-11 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 5 – INSTALLATION FOR ENGINE POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-1 Installing Welder/Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-2 Grounding Generator to Truck or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

5-4 Fuel Valve Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-5 Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-6 Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-7 Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-8 Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 6 – INSTALLATION FOR UTILITY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6-1 Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6-2 Multi-Voltage Plug (MVP) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6-3 Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-4 Input Power Extension Cord Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-5 Connecting 120 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-6 Connecting 1-Phase Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 7 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7-1 Front Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 8 – OPERATING AUXILIARY EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-1 Generator Power Panel Receptacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-2 GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SECTION 9 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9-2 Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9-3 Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9-4 Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9-5 Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9-6 Adjusting Engine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9-7 Reorienting Recoil Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

TABLE OF CONTENTS

SECTION 10 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11-1 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 12 – ELECTRICAL DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION 13 – GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 14 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

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

1-1. Symbol Usage

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

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

NOTICE – Indicates statements not related to personal injury.

Indicates special instructions.

F

1-2. Arc Welding Hazards

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

Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children,
away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.

cuits 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.

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

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

l Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

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

unit.

l 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!

l Do not connect to any electrical distribution system normally sup-

plied by utility power unless a proper transfer switch and ground­ing procedure are employed.

The input power circuit and machine internal cir-

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

l Disconnect input power or stop engine before installing or servic-

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

l Properly install, ground, and operate this equipment according to

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

l 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.

l When making input connections, attach proper grounding conduc-

tor first—double-check connections.

l Keep cords dry, free of oil and grease, and protected from hot met-

al and sparks.

l Frequently inspect input power cord and ground conductor for

damage or bare wiring —replace immediately if damaged— bare
wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

l Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

l Do not connect more than one electrode or work cable to any sin-

gle weld output terminal. Disconnect cable for process not in use.

l Use GFCI protection when operating auxiliary equipment. Test

GFCI receptacles at high speed.

HOT PARTS can burn.

l Do not touch hot parts bare handed.
l Allow cooling period before working on equipment.
l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

OM-284208 Page 1

FLYING METAL OR DIRT can injure

eyes.

l Welding, chipping, wire brushing, and grinding

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

l Wear approved safety glasses with side shields even under your

welding helmet.

FUMES AND GASES can be

hazardous.

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

l Keep your head out of the fumes. Do not breathe the fumes.
l Ventilate the work area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

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

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

l Work in a confined space only if it is well ventilated, or while wear-

ing 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.

l Do not weld in locations near degreasing, cleaning, or spraying

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

l Do not weld on coated metals, such as galvanized, lead, or cadmi-

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

BUILDUP OF GAS can injure or kill.

l Shut off compressed gas supply when not in use.

l Always ventilate confined spaces or use approved

air-supplied respirator.

ARC RAYS can burn eyes and skin.

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

l Wear an approved welding helmet fitted with a proper shade of fil-

ter 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).

l Wear approved safety glasses with side shields under your

helmet.

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

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

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

WELDING can cause fire or

explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding arc. The flying

sparks, hot workpiece, and hot equipment can cause fires and burns.

OM-284208 Page 2

Accidental contact of electrode to metal objects can cause sparks, ex­plosion, overheating, or fire. Check and be sure the area is safe be­fore doing any welding.

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

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

l Do not cut or weld on tire rims or wheels. Tires can explode if

heated. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

l Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 (see Safety Standards).

l Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

l 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.

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

tact tip when not in use.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

l Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

l Wear approved ear protection if noise level is high.

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

l Wearers of Pacemakers and other Implanted Med-

ical Devices should keep away.

l Implanted Medical Device wearers should consult their doctor and

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

CYLINDERS can explode if
damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the weld-

ing process, be sure to treat them carefully.

l Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

1-3. Engine Hazards

l Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the
valve.

l Keep protective cap in place over valve except when cylinder is in

use or connected for use.

l Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

l Read and follow instructions on compressed gas cylinders, asso-

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

BATTERY EXPLOSION can injure.

l Always wear a face shield, rubber gloves, and pro-

tective clothing when working on a battery.

l Stop engine before disconnecting or connecting

battery cables, battery charging cables (if applica-

ble), or servicing battery.

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

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

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

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

l Follow battery manufacturer’s instructions when working on or

near a battery. See Battery Service Manual (listed in Safety Stand­ards) for additional information.

FUEL can cause fire or explosion.

ENGINE HEAT can cause fire.

l Stop engine and let it cool off before checking or

adding fuel.

l Do not add fuel while smoking or if unit is near any

sparks or open flames.

l Do not overfill tank — allow room for fuel to expand.
l Do not spill fuel. If fuel is spilled, clean up before starting engine.
l Dispose of rags in a fireproof container.
l Always keep nozzle in contact with tank when fueling.
l Do not locate unit on, over, or near combustible surfaces or

flammables.

l Keep exhaust and exhaust pipes way from flammables.

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

keep engine from kicking back or starting.

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

components.

EXHAUST SPARKS can injure.

l Do not let engine exhaust sparks cause fire.

l Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

HOT PARTS can burn.

l Do not touch hot parts bare handed.

l Allow cooling period before working on equipment.

l 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.

l If possible, check coolant level when engine is cold

to avoid scalding.

l Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told otherwise in main­tenance section or engine manual).

l If the engine is warm, checking is needed, and there is no overflow

tank, follow the next two statements.

l Wear safety glasses and gloves and put a rag over radiator cap.

l Turn cap slightly and let pressure escape slowly before completely

removing cap.

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts,

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

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

guards for maintenance and troubleshooting as necessary.

l To prevent accidental starting during servicing, disconnect nega-

tive (-) battery cable from battery.

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

parts.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

Using a generator indoors CAN KILL

YOU IN MINUTES.

l Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

l NEVER use inside a home or garage, EVEN IF
doors and windows are open.

l Only use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and

EYES.

l Do not tip battery.

l Replace damaged battery.

l Flush eyes and skin immediately with water.

OM-284208 Page 3

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can

injure or kill.

l Incorrect installation or operation of this unit could

result in equipment failure and personal injury. On-

ly qualified persons should install, operate, and
service this unit according to its Owner’s Manual, industry stand­ards, and national, state, and local codes.

l 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.

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

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

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

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

l Do not modify or alter compressor or manufacturer-supplied

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

l Use only components and accessories approved by the

manufacturer.

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

equipment connected to the compressed air system.

l 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.

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

COMPRESSED AIR can injure or kill.

l Before working on compressed air system, turn off

and lockout/tagout unit, release pressure, and be

sure air pressure cannot be accidentally applied.

l Relieve pressure before disconnecting or connect-

ing air lines.

l Check compressed air system components and all

connections and hoses for damage, leaks, and

wear before operating unit.

l Do not direct air stream toward self or others.

l 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.

l Use soapy water or an ultrasonic detector to search for leaks—

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

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting unit.

l If ANY air is injected into the skin or body seek medical help

immediately.

BREATHING COMPRESSED AIR can

injure or kill.

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

TRAPPED AIR PRESSURE AND

WHIPPING HOSES can injure.

l Release air pressure from tools and system before

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

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

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

parts.

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

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

l Have only qualified people remove guards or covers for mainte-

nance and troubleshooting as necessary.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

HOT PARTS can burn.

l Do not touch hot compressor or air system parts.
l Allow cooling period before working on equipment.
l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

READ INSTRUCTIONS.

l 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.

l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo­cal codes.

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

FIRE OR EXPLOSION hazard.

l Do not install or place unit on, over, or near com-

bustible surfaces.

l Do not install unit near flammables.

l Do not overload building wiring —be sure power

supply system is properly sized, rated, and protected to handle
this unit.

OM-284208 Page 4

l Use correct procedures and equipment of adequate capacity to lift

and support unit.

l If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

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

when working from an aerial location.

FALLING EQUIPMENT can injure.

l Use lifting eye to lift unit and properly installed ac-

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

l Follow the guidelines in the Applications Manual for the Revised

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

OVERHEATING can damage motors.

l Turn off or unplug equipment before starting or

stopping engine.

l Do not let low voltage and frequency caused by

low engine speed damage electric motors.

l Use only equipment suitable for operation on 60 or 50/60 Hz

power.

FLYING SPARKS can injure.

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

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

l Sparks can cause fires—keep flammables away.

MOVING PARTS can injure.

l Keep away from moving parts.

l Keep away from pinch points such as drive rolls.

BATTERY CHARGING OUTPUT and

BATTERY EXPLOSION can injure.

Battery charging not present on all models.

HIGH PRESSURE FLUIDS can injure

or kill.

l Engine fuel system components can be under high

pressure.

l Before working on fuel system, turn off engine to

release pressure.

l If any fluid is injected into the skin or body seek medical help

immediately.

WELDING WIRE can injure.

l Do not press gun trigger until instructed to do so.
l Do not point gun toward any part of the body, other

people, or any metal when threading welding wire.

OVERUSE can cause

OVERHEATING.

l Allow cooling period; follow rated duty cycle.
l Reduce current or reduce duty cycle before start-

ing to weld again.

l Do not block or filter airflow to unit.

STATIC (ESD) can damage PC

boards.

l Put on grounded wrist strap BEFORE handling

boards or parts.

l Use proper static-proof bags and boxes to store,

move, or ship PC boards.

tective clothing when working on a battery.

l Always wear a face shield, rubber gloves, and pro-

l Stop engine before disconnecting or connecting battery cables,

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

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

it has a battery charging feature designed for this purpose.

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

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

l Follow battery manufacturer’s instructions when working on or

near a battery. See Battery Service Manual (listed in Safety Stand­ards) for additional information.

l Have only qualified persons do battery charging work.
l If battery is being removed from a vehicle for charging, disconnect

negative (-) cable first and connect it last. To prevent an arc, make
sure all accessories are off.

l Charge lead-acid batteries only. Do not use battery charger to sup-

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

l Do not charge a frozen battery.
l Do not use damaged charging cables.
l Do not charge batteries in a closed area or where ventilation is

restricted.

l Do not charge a battery that has loose terminals or one showing

damage such as a cracked case or cover.

l Before charging battery, select correct charger voltage to match

battery voltage.

l Set battery charging controls to the Off position before connecting

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

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

parts.

TILTING OF TRAILER can injure.

l Use tongue jack or blocks to support weight.
l Properly install welding generator onto trailer ac-

cording to instructions supplied with trailer.

RECYCLE.

l Recycle or dispose of used liquids in an environ-

mentally safe way. This is especially true for en­gine fluids such as drain oil and used coolant; this
is also important for coolant from torch/gun cooling

systems.

l Contact your local recycling office or your local distributor for infor-

mation about how to dispose of parts and equipment in an envi­ronmentally safe way.

READ INSTRUCTIONS.

l 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.

l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo­cal codes.

H.F. RADIATION can cause

interference.

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

gation, safety services, computers, and communi­cations equipment.

l Have only qualified persons familiar with electronic equipment per-

form this installation.

l The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

OM-284208 Page 5

l If notified by the FCC about interference, stop using the equipment

at once.

l Have the installation regularly checked and maintained.
l 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.

l Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,

computers, and computer-driven equipment such
as robots.

1-6. California Proposition 65 Warnings

WARNING – This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65Warnings.ca.gov.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

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

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian
Standards Association. Website: www.csagroup.org.

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

stitute. Website: www.ansi.org.

l Be sure all equipment in the welding area is electromagnetically

compatible.

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

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

l Locate welding operation 100 meters from any sensitive electronic

equipment.

l Be sure this welding machine is installed and grounded according

to this manual.

l 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.

For Diesel Engines:

WARNING – Breathing diesel engine exhaust exposes you
to chemicals known to the state of California to cause can­cer and birth defects or other reproductive harm.

ll Always start and operate the engine in a well−ventilated

area.

ll If in an enclosed area, vent the exhaust to the outside.
ll Do not modify or tamper with the exhaust system.
ll Do not idle the engine except as necessary.

For more information, go to www.P65Warnings.ca.gov/diesel.

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

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub­part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U. S. Consumer Prod-

uct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National Flu­id Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Web­site: www.batterycouncil.org.

ROM 2022–01

1-8. EMF Information

Electric current flowing through any conductor causes localized elec­tric and magnetic fields (EMF). The current from arc welding (and al­lied processes including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF field around the
welding circuit. EMF fields can interfere with some medical implants,
e.g. pacemakers. Protective measures for persons wearing medical
implants have to be taken. For example, restrict access for passers

−by or conduct individual risk assessment for welders. All welders
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit:

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

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

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

OM-284208 Page 6

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

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

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

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

About Implanted Medical Devices:

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

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

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

2-1. Symboles utilisés

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

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

AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.

Indique des instructions spécifiques.

F

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

Les symboles représentés ci-dessous sont utilisés dans ce
manuel pour attirer l’attention et identifier les dangers pos­sibles. En présence de ce symbole, prendre garde et suivre
les instructions afférentes pour éviter tout risque. Les
consignes de sécurité présentées ci-après ne font que résu­mer l’information contenue dans les Normes de sécurité
principales. Lire et suivre toutes les Normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une per­sonne qualifiée est définie comme celle qui, par la posses­sion d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de re­connaître et d’éviter les risques inhérents.

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

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques
peut provoquer une électrocution ou des blessures
graves. L’électrode et le circuit de soudage sont

cuit 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.

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

tant pas de trous.

l 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.

l Ne pas utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

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

MENT si le procédé de soudage le demande.

l 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.

l 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

sous tension dès que l’appareil est sur ON. Le cir-

Ce groupe de symboles veut dire Avertissement! Attention! DAN­GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE­CES CHAUDES. Reportez-vous aux symboles et aux directives ci­dessous afin de connaître les mesures à prendre pour éviter tout
danger.

de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi-automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas,
un poste courant continu de type CV est recommandé. Et, ne pas
travailler seul!

l Ne brancher aucun système de distribution électrique normale-

ment fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.

l 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).

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

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

l Toujours vérifier la terre du cordon d’alimentation - Vérifier et s’as-

surer 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.

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

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

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

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

l Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -,
le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraî­ner la mort.

l Mettre l’appareil hors tension quand on ne l’utilise pas.
l Ne pas utiliser des câbles usés, endommagés, sous dimension-

nés ou réparés.

l Ne pas enrouler les câbles autour du corps.
l 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.

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

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

l Ne pas toucher des porte électrodes connectés à deux machines

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

l N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

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

OM-284208 Page 7

l Ne pas toucher aux portes-électrodes qui sont raccordés à deux

machines à souder en même temps, car cela entraîne la présence
d’une tension de circuit-ouvert double.

l Porter un harnais de sécurité quand on travaille en hauteur.
l Maintenir solidement en place tous les panneaux et capots.
l 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.

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

contact avec tout objet métallique.

l Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

l Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliai-

res. Testez les prises GFCI à haute vitesse.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues.
l Prévoir une période de refroidissement avant de

travailler à l’équipement.

l 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.

l 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.

l 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.

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

niveau de l’arc pour l’évacuation des fumées et des gaz de sou­dage. Pour déterminer la bonne ventilation, il est recommandé de
procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.

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

approuvé.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

l 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.

l 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.

l 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

OM-284208 Page 8

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.

l Fermer l’alimentation du gaz comprimé en cas de

non utilisation.

l 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.

l Porter un casque de soudage approuvé muni de verres filtrants

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

l Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-

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

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des panta­lons sans revers, des chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés
tels que des réservoirs, tambours ou des conduites
peut provoquer leur éclatement. Des étincelles

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

l 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.

l Ne pas souder dans un endroit là où des étincelles peuvent tom-

ber sur des substances inflammables.

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

de métal chaud.

l Des étincelles et des matériaux chauds du soudage peuvent faci-

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

l Ne pas couper ou souder des jantes ou des roues. Les pneus peu-

vent exploser s’ils sont chauffés. Les jantes et les roues réparées
peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les
normes de sécurité.

l 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).

l Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par
exemple).

l 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.

l Ne pas utiliser le poste de soudage pour dégeler des conduites

gelées.

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

électrode ou couper le fil à la pointe de contact.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des panta­lons sans revers, des chaussures hautes et une casquette.

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

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

l Une fois le travail achevé, assurez-vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

l Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

l 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.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

Le BRUIT peut endommager l’ouïe.

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

l Porter des protections approuvées pour les oreilles

si le niveau sonore est trop élevé.

Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants
médicaux.

l Les porteurs de stimulateurs cardiaques et autres

implants médicaux doivent rester à distance.

l Les porteurs d’implants médicaux doivent consulter leur médecin

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

Si des BOUTEILLES sont
endommagées, elles pourront
exploser.

Des bouteilles de gaz comprimé protecteur
contiennent du gaz sous haute pression. Si une

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

l 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.

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

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

l Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

l Ne jamais souder une bouteille pressurisée - risque d’explosion.
l Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

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

l Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière lerégulateur lors
de l’ouverture de la vanne.

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

d’utilisation ou de branchement de la bouteille.

l Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter les
bouteilles.

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

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

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peut

provoquer des blessures.

l Toujours porter une protection faciale, des gants

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

l 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.

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

la batterie.

l 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.

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

dernier lieu.

l Les sources d’étincelles, flammes nues, cigarettes et autres sour-

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

l Suivre les instructions du fabricant de la batterie lors d’opérations

sur une batterie ou à proximité de celle-ci. Voir le manuel de ser­vice de batterie (indiqué dans Normes de sécurité) pour plus
d’informations.

l Arrêter le moteur avant de vérifier le niveau de carburant ou de

faire le plein.

l Ne pas faire le plein en fumant ou proche d’une source d’étincelles

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

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

remplissage.

LE CARBURANT MOTEUR peut
provoquer un incendie ou une
explosion. LA CHALEUR DU
MOTEUR peut provoquer un
incendie.

OM-284208 Page 9

l Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces

inflammables.

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

l 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.

Les PIÈCES MOBILES peuvent

causer des blessures.

l S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs deprotection.

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

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

l Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien, débrancher le câble négatif (-) de batterie delaborne.

l Ne pas approcher les mains, cheveux, vêtements lâches etoutils

des organes mobiles.

l Remettre en place les portes, panneaux, recouvrements ou dispo-

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

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

mise en route accidentelle du moteur.

l Bloquer le volant moteur pour éviter sa rotation lors d’une inter-

vention sur le générateur.

LES ÉTINCELLES À
L’ÉCHAPPEMENT peuvent
provoquer un incendie.

l Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

l Utiliser uniquement un pare-étincelles approuvé - voir codes en

vigueur.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues.
l Prévoir une période de refroidissement avant de

travailler à l’équipement.

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.

l Il est préférable de vérifier le liquide de refroidisse-

ment une fois le moteur refroidi pour éviter de se

brûler.

l 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).

l Si le moteur est chaud et que le liquide doit être vérifié, opérer

comme suivant.

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

le bouchon du radiateur.

l 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.

l Les fumées d’un groupe autonome contient du mo-

noxyde de carbone. C’est un poison invisible et

inodore.

l JAMAIS utiliser dans une maison ou garage, même avec les por-

tes et fenêtres ouvertes.

l 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.

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

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

2-4. Dangers liés à l’air comprimé

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

l 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.

l 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.

l Avant d’intervenir sur le circuit d’air comprimé, couper l’alimenta-

tion 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.

l 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.

l 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.

OM-284208 Page 10

l Utiliser uniquement des composants et accessoires homologués

par le fabricant.

l 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.

l Ne pas intervenir sous ou autour d’un équipement qui n’est soute-

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

MÉTAL CHAUD provenant du
découpage ou du gougeage à l’arc
risque de provoquer un incendie ou
une explosion.

l Ne pas découper ou gouger à proximité de pro-

duits inflammables.

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

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

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

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

l Détendre la pression avant de débrancher ou de

brancher des canalisations d’air.

l Avant d’utiliser l’appareil, contrôler lescomposants du circuit d’air

comprimé, lesbranchements et les flexibles en recherchant tout si­gne de détérioration, de fuite et d’usure.

l Ne pas diriger un jet d’air vers soi-même ou vers autrui.
l Pour intervenir sur un circuit d’air comprimé, porter unéquipement

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

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

tecteur à ultrasons, jamais les mains nues. En cas dedétection de
fuite, ne pas utiliser l’équipement.

l Remettre les portes, panneaux, recouvrements ou dispositifs de-

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

l En cas d’injection d’air dans la peau ou le corps, demander immé-

diatement une assistance médicale.

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

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

ou gouger ainsi que pour l’outillage pneumatique.

Une PRESSION D’AIR RÉSIDUELLE
ETDES FLEXIBLES QUI FOUETTENT
risquent de provoquer des
blessures.

l Détendre la pression pneumatique des outils et cir­cuits avant d’entretenir, ajouter ou changer des accessoires et
avant d’ouvrir le bouchon de vidange ou de remplissage d’huile
ducompresseur.

Les PIÈCES MOBILES peuvent

causer des blessures.

l S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protection.

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

des organes mobiles.

l Avant d’intervenir sur le circuit d’air comprimé, couper l’alimenta-

tion 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.

l Demander seulement à un personnel qualifié d’enlever les disposi-

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

l Remettre en place les portes, panneaux, recouvrements ou dispo-

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

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

l Ne pas toucher de pièces chaudes du compresseur

ou du circuit d’air.

l Prévoir une période de refroidissement avant d’in-

tervenir sur l’équipement.

l 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.

LIRE LES INSTRUCTIONS.

l 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.

l N’utiliser que des pièces de remplacement provenant du fabricant.

l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

2-5. Symboles de dangers supplémentaires en relation avec l’installation, le

fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

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

mité de surfaces inflammables.

l Ne pas installer l’appareil à proximité de produits
inflammables

l Ne pas surcharger l’installation électrique – s’assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

l Utiliser seulement l’anneau de levage pour soule-

ver l’appareil et des accessoires correctement in-

stallés, non pas les bouteilles de gaz. Ne pas
dépasser les capacités maximales de l’anneau de levage (voir
Spécifications).

l Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

l En utilisant des fourches de levage pour déplacer l’unité, s’assurer

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

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

mobiles lors de toute opération en hauteur.

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

de levage NIOSH révisée (Publication № 94–110) lors du levage
manuelle de pièces ou équipements lourds.

LE SURCHAUFFEMENT peut

endommager le moteur électrique.

l Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

l Ne pas laisser tourner le moteur trop lentement
sous risque d’endommager le moteur électrique à cause d’une
tension et d’une fréquence trop faibles.

OM-284208 Page 11

l Utiliser uniquement des équipements adéquats pour un fonction-

nement avec une alimentation de 50/60 ou de 60 Hz.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

l Porter un écran facial pour protéger le visage et

les yeux.

l 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.

l Les étincelles risquent de causer un incendie - éloigner toute sub-

stance inflammable.

Les PIÈCES MOBILES peuvent

causer des blessures.

l Ne pas s’approcher des organes mobiles.

l Ne pas s’approcher des points de coincement tels

que des rouleaux de commande.

LA SORTIE DE RECHARGE et
L’EXPLOSION DE LA BATTERIE
peuvent provoquer des blessures.

La recharge de batterie n’existe pas sur tous les
modèles.

l Toujours porter une protection faciale, des gants en caoutchouc et

vêtements de protection lors d’une intervention sur la batterie.

l 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.

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

la batterie.

l 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.

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

dernier lieu.

l Les sources d’étincelles, flammes nues, cigarettes et autres sour-

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

l Suivre les instructions du fabricant de la batterie lors d’opérations

sur une batterie ou à proximité de celle-ci. Voir le manuel de ser­vice de batterie (indiqué dans Normes de sécurité) pour plus
d’informations.

l Les opérations de charge de batterie ne doivent être effectuées

que par des personnes qualifiées.

l Pour enlever la batterie d’un véhicule pour la recharge, débran-

cher tout d’abord le câble négatif (-) et le rebrancher en dernier
lieu. Pour éviter un arc, s’assurer que tous les accessoires sont
débranchés.

l Ne charger que des batteries plomb-acide. Ne pas utiliser le char-

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

l Ne pas charger une batterie gelée.
l Ne pas utiliser de câbles de charge endommagés.
l Ne pas charger des batteries dans un espace fermé ou en l’ab-

sence d’une ventilation.

l Ne pas charger une batterie dont les bornes sont desserrées ou

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

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

correspondant à la tension de la batterie.

OM-284208 Page 12

l 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.

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

des pièces mobiles du véhicule.

LES LIQUIDES PRESSURISÉS

peuvent blesser ou tuer.

l Les composants du système d’alimentation peu-

vent contenir du carburant sous pression élevée.

l Avant d’intervenir sur le système d’alimentation de

carburant, arrêter le moteur pour dépressuriser le système.

l En cas d’injection de tout liquide sous la peau ou dans le corps,

solliciter une aide médicale sur le champ.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

l Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

l Ne pas diriger le pistolet vers soi, d’autres person-

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

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

l Laisser l’équipement refroidir ; respecter le facteur

de marche nominal.

l Réduire le courant ou le cycle opératoire avant de

recommancer le soudage.

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

LES CHARGES
ÉLECTROSTATIQUES peuvent
endommager les circuits imprimés.

l Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

l Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE
peut provoquer des blessures.

l Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

l Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

RECYCLER.

l Recycler ou éliminer les liquides usagés d’une ma-

nière respectueuse de l’environnement. Cela est
particulièrement vrai pour les fluides du moteur tels
que l’huile de vidange et le liquide de refroidisse-

ment usagés ; ceci est également important pour le liquide de re­froidissement provenant des systèmes de refroidissement de la
torche/du pistolet.

l Contactez votre bureau de recyclage local ou votre distributeur lo-

cal pour obtenir des informations sur la manière de mettre au re­but les pièces et l’équipement d’une manière respectueuse de
l’environnement.

LIRE LES INSTRUCTIONS.

l 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.

l N’utiliser que des pièces de remplacement provenant du fabricant.

l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

l Le rayonnement haute fréquence (H.F.) peut pro-

voquer des interférences avec les équipements de

radio-navigation et de communication, les services de sécurité et
les ordinateurs.

l Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner
l’installation.

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

qualifié les interférences résultant de l’installation.

l Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

l Effectuer régulièrement le contrôle et l’entretien de l’installation.
l 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.

commandé par ordinateur tel que les robots.

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

compatible électromagnétiquement.

l 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).

l Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

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

conformément à ce mode d’emploi.

l En cas d’interférences après avoir pris les mesures précédentes,

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

2-6. Proposition californienne 65 Avertissements

AVERTISSEMENT – ce produit peut vous exposer à des pro­duits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malforma­tions ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

Pour les moteurs diesel :

Pour plus d’informations, consulter www.P65Warnings.ca.gov/diesel.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

l L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement

AVERTISSEMENT – les gaz d’échappement de moteurs die­sel vous exposent à des produits chimiques, reconnus par
l’État de Californie comme cancérigènes et sources de mal­formations ou d’autres troubles de la reproduction.

ll Toujours démarrer et faire tourner le moteur dans une

zone bien aérée.

ll Si la zone est fermée, diriger l’échappement vers

l’extérieur.

ll Ne pas modifier ni altérer le système d’échappement.
ll Ne pas faire tourner le moteur au ralenti, sauf si

nécessaire.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

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

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www. csa-

group.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian
Standards Association. Website: www.csagroup.org.

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

titute. Website: www.ansi.org.

2-8. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des
champs électromagnétiques (CEM) à certains endroits. Le courant is­su d’un soudage à l’arc (et de procédés connexes, y compris le sou­dage par points, le gougeage, le découpage plasma et les opérations

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

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub­part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U. S. Consumer Pro-

duct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National
Fluid Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Web­site: www.batterycouncil.org.

ROM_fre 2022–01

de chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques pro­duits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour

OM-284208 Page 13

les porteurs d’implants médicaux doivent être prises: par exemple,
des restrictions d’accès pour les passants ou une évaluation indivi­duelle des risques pour les soudeurs. Tous les soudeurs doivent ap­pliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage:

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

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

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

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-284208 Page 14

Complete Parts List is available at www.MillerWelds.com

Become trained and read the instructions before working on the
machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground
terminal.
Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

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

Safe87 2012 07

Become trained and read the instructions before working on the
machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground
terminal.
Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

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

Safe87 2012 07

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

Safe88 2012 07

%

Percent

Increase

F

SECTION 3 – DEFINITIONS

3-1. Additional Safety Symbol Definitions

Some symbols are found only on CE products.

F

3-2. Miscellaneous Symbol Definitions

Warning! Watch Out! There are possible hazards as shown by the
symbols.

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

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

Amperage

Voltage

Rated No-Load Volt-

age (OCV)

Conventional Load

Voltage

Rated Welding

Current

Duty Cycle

Negative

Positive

Direct Current (DC)

Circuit Breaker

Supplementary

Protector

Read Operator’s

Manual

Shielded Metal Arc

Welding (SMAW)

Fuel

Fuel Shutoff

Engine Oil

Engine Choke

Air Filter

Engine

Engine Stop

Engine Start

Idle (Slow)

Run (Fast)

Temperature

Increase

Rated Supply

Voltage

Rated Load Speed

Rated No-Load

Speed

Alternating Current

Protective Earth

(Ground)

(AC)

Engine

Engine RPM

Rated Idle Speed

Rated Maximum

Supply Current

OM-284208 Page 15

Complete Parts List is available at www.MillerWelds.com

F

Maximum Effective

Supply Current

Power

Internal Protection

Rating

Reduced Rated No-

Load Voltage

Hertz

Single Phase

Suitable For Weld-

ing In An Environ-

ment With An

Increased Risk Of

Electric Shock

Line Connection

Off

On

Percent

OM-284208 Page 16

Complete Parts List is available at www.MillerWelds.com

F

SECTION 4 – SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the power shift box. Use rating label to determine input power require­ments and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at

https://www.millerwelds.com/eula and are incorporated by reference herein.

4-3. Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriate­ness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific require­ments. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warran­ties including any implied warranty of fitness for a particular purpose.

4-4. Weld, Power, And Engine Specifications

This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C).

F

Welding Mode

CC/DC 30–185 A

Weld Output

Range

Rated Welding

Output

185 A, 26.4 V,

20% Duty Cycle

110 A, 24.4 V,

100% Duty Cycle

Maximum Open-

Circuit Voltage

58

Generator

Power Rating

Single-Phase, 6.5

kVA/kW (Peak)

6.2 kVA/kW (Con­tinuous) 20x2/26
A, 120/240 VAC,

60 Hz

Fuel Capacity Engine

Kohler CH440

6.25 gal (23 L)
Tank

Air-Cooled, One-

Cylinder, Four­Cycle, 13.4 HP

Gasoline Engine

Electric Start

4-5. Unit Specifications For Utility Power

Do not use information in unit specifications table to determine electrical service requirements. See Sections 6-3, 6-6, and 6-5 for informa-

F

tion on connecting input power.

Input Voltage Amperage Range Rated Welding Output

120 VAC 30–100

240 VAC 30–185

90 A, 23.6 V, 40% Duty

Cycle

185 A, 26.4 V, 20% Duty

Cycle

110 A, 24.4 V, 100% Duty

Cycle

Maximum Open-Circuit

Voltage DC

58 22.7

58 26.0

Amperes Input At Rated

Load Output, 50/60 Hz,

Single-Phase

4-6. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use.

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

–4 to 122°F (–20 to 50°C) –40 to 131°F (–40 to 55°C)

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

OM-284208 Page 17

Complete Parts List is available at www.MillerWelds.com



A complete Parts List is available at www.MillerWelds.com

280477

A

B

C

D

E

F

G

280477

0

20

40

60

80

100

120

140

160

180

200

0 20 40 60 80 100

OUTPUT AMPERES

% DUTY CYCLE

284900-A

1

F

4-7. Dimensions, Weights, And Operating Angles

Dimensions

Height 24.75 in. (629 mm)

Width 20-3/32 in. (510 mm)

Depth 31.25 in. (794 mm)

A 31.25 in. (794 mm)
B 7-39/64 in. (193 mm)
C 15-3/32 in. (383 mm)
D 20-3/32 in. (510 mm)
E 1-11/32 in. (34 mm)
F 16-27/32 in. (428 mm)
G 13/32 in. (10 mm) Dia.

Weight

300 lb (136 kg)

Lifting Eye Weight Rating:

430 lb (195 kg)

Engine End

4-8. Duty Cycle And Overheating

Do not exceed tilt angles or engine could
be damaged or unit could tip.

Do not move or operate unit where it could
tip.

OM-284208 Page 18

1 100% Duty Cycle

Duty cycle is the percentage of 10 minutes
that unit can weld at rated load without
overheating.

This unit is rated for welding at 110 am-

F

peres continuously with engine power.

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

4-9. Volt-Ampere Curve

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300 350

VOLTS

AMPS

284209-A

XAMNIM



A complete Parts List is available at www.MillerWelds.com

279102-A

0

5

10

15

20

25

30

35

0 50 100 150 200 250 300

DC VOLTS

DC AMPERES

MIN

MAX

268 591

0

50

100

150

200

250

300

0 10 20 30 40 50 60 70 80

VOLTS

AMPS

240 Volt

120 Volt

Complete Parts List is available at www.MillerWelds.com

F

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

4-10. Generator Power Curve

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

OM-284208 Page 19

4-11. Fuel Consumption

0.00

0.20

0.40

0.60

0.80

1.00

0 20 40 60 80 100 120 140 160 180

US Gal./Hr.

DC WELD AMPERES AT RATED DUTY CYCLE

IDLE

284269

284269

Fuel Consumption While Welding

Complete Parts List is available at www.MillerWelds.com

F

Fuel Consumption — Auxiliary Power

OM-284208 Page 20

Complete Parts List is available at www.MillerWelds.com

1 Lifting Handles

Use handles to lift unit.

2 Hand Cart

Use cart or similar device to move
unit.

! Do not install unit where air

flow is restricted or engine
may overheat.

! Do not move or operate unit

where it could tip.

! Always securely fasten

welder/generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes

1

2

1

1 Lifting Handles

Use handles to lift unit.

2 Hand Cart

Use cart or similar device to move
unit.

! Do not install unit where air

flow is restricted or engine
may overheat.

! Do not move or operate unit

where it could tip.

! Always securely fasten

welder/generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes



Go to MillerWelds.com for
more information on truck
installations.

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

1

2

1

F

SECTION 5 – INSTALLATION FOR ENGINE POWER

5-1. Installing Welder/Generator

Movement

Location And Airflow

1 Lifting Handles

Use handles to lift unit.

2 Hand Cart

Use cart or similar device to move unit.

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

Do not move or operate unit where
it could tip.

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

Go to MillerWelds. com for more infor-

F

mation on truck installations.

OM-284208 Page 21

Complete Parts List is available at www.MillerWelds.com

1-1. Grounding Generator To Truck Or Trailer Frame

1

3

2

GND/PE

GND/PE

1 2

2

3

F

5-2. Grounding Generator to Truck or Trailer Frame

Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.

Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding
Generators.

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

1 Equipment Grounding Terminal (On

Front Panel)

2 Grounding Cable (Not Supplied)

5-3. Grounding When Supplying Building Systems

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

F

vehicle frame by metal-to-metal
contact.

1 Equipment Grounding Terminal

2 Grounding Cable

Use #8 AWG or larger insulated copper wire.

3 Ground Device

Use ground device as stated in electri-

F

cal codes.

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

Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Port­able And Vehicle Mounted Welding
Generators.

OM-284208 Page 22

F

268 699 / 267 206

1

268 699

+

5-4. Fuel Valve Positions

5-5. Connecting The Battery

Complete Parts List is available at www.MillerWelds.com

1 Fuel Valve

F

Always close fuel valve after stopping

unit. Moving unit may cause carburetor
flooding and make starting difficult.

1/2 in.

Turn Engine Switch to Off.

Connect negative (-) battery cable
last.

OM-284208 Page 23

F









5-6. Engine Prestart Checks

Complete Parts List is available at www.MillerWelds.com

Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W-30 synthetic blend engine oil.

1 Fuel Valve

Open valve.

F

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

2 Full

3 Low

4 Filler Neck

5 Bring Level Up To Point Of Overflow

Close fuel valve before moving unit or

carburetor may flood and make starting
difficult.

After fueling, check oil with unit on level
surface.

To check oil, remove dipstick and wipe off oil.
Reinsert dipstick into filler neck tube as far
as possible without threading cap. Pull dip­stick out and check oil level. If oil is not up to
full mark on dipstick, add oil.

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

To improve cold weather starting:

F

Keep battery in good condition. Store
battery in warm area off concrete sur­face (if equipped).

Use correct grade oil for cold weather.

OM-284208 Page 24

F



A complete Parts List is available at www.MillerWelds.com

280477

1

2

5-7. Weld Output Terminals

Complete Parts List is available at www.MillerWelds.com

Stop engine before connecting to
weld output terminals.

Do not use worn, damaged, under­sized, or repaired cables.

1 Positive (+) Weld Output Terminal

2 Negative (-) Weld Output Terminal

For Direct Current Electrode Positive
(DCEP), connect work cable to Negative (-)
terminal and electrode holder to Positive (+)
terminal.

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

The weld output terminals require Tweco
style connectors.

5-8. Selecting Cable Sizes*

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

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***

2

)

350 ft

(105 m)

(120 m)

100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m)

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)

* 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.

2

( ) = mm

***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.

10 - 60%

Duty Cycle

AWG (mm

for metric use.

2

)

60 - 100%

Duty Cycle

AWG (mm2)

10 - 100% Duty Cycle AWG (mm

400 ft

OM-284208 Page 25

F



A complete Parts List is available at www.MillerWelds.com

SECTION 2 INSTALLATION FOR UTILITY POWER

1

2

3

2

 A complete Parts List is available at www.MillerWelds.com

4

1

2

3

2

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

2 in.
(51 mm)

SECTION 6 – INSTALLATION FOR UTILITY POWER

6-1. Selecting A Location

Complete Parts List is available at www.MillerWelds.com

Movement

Location And Airflow

Do not move or operate unit where
it could tip.

Special installation may be re­quired where gasoline or volatile
liquids are present - see NEC Ar­ticle 511 or CEC Section 20.

1 Lifting Forks

Extend forks beyond opposite side of unit.

2 Lifting Handles

Use handles to lift unit.

3 Hand Cart

Use cart or similar device to move unit.

4 Line Disconnect Device

Locate unit near correct input power supply.

OM-284208 Page 26

Complete Parts List is available at www.MillerWelds.com

3

2

7

4

5

6

1

Ref. 803812-C

3

2

7

4

5

6

1

F

6-2. Multi-Voltage Plug (MVP) Connection

Selecting Plug

Connecting Plug To Power Cord

Do not cut off power cord connector
and rewire. The power cord connec­tor and plugs will work with stand­ard NEMA receptacles. Modifying
power cord, connector, and plugs
will void product warranty.

Selecting Plug

1 Power Cord Connector From Welding

Power Source

Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.

2 Plug - NEMA Type 5-15P
3 Receptacle - NEMA Type 5-15R (Cus-

tomer Supplied)
4 Plug - NEMA Type 5-20P (Optional)
5 Receptacle - NEMA Type 5-20R (Cus-

tomer Supplied)
6 Plug - NEMA Type 6-50P
7 Receptacle - NEMA Type 6-50R (Cus-

tomer Supplied)

Follow electrical service guide for
230 VAC. Do not use plug rating to
size branch circuit protection.

Connecting Plug To Power Cord

Align arrow on plug with arrow on power
cord connector. Push together.

Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.

Connect plug to receptacle.

OM-284208 Page 27

Complete Parts List is available at www.MillerWelds.com

F

6-3. Electrical Service Guide

NOTICE – Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual in­put voltage is outside this range, output may not be available.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen­dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual
branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

50/60 Hz 1–Phase 50/60 Hz 1–Phase

Rated Supply Voltage (V) 120 240
Rated Maximum Supply Current I
Rated Effective Supply Current I
Maximum Recommended Standard Fuse Rating In Amperes
Time Delay Fuses
Normal Operating Fuses

2

3

Maximum Recommended Supply Conductor Length In Feet (Meters)
Raceway Installation
Minimum Supply Conductor Size In AWG (mm
Minimum Grounding Conductor Size In AWG (mm
Flexible Cord Installation
Minimum Supply Conductor Size In AWG (mm

Reference: 2023 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 "Time-Delay" fuses are UL class "RK5" . See UL 248.
3 "Normal Operating" (general purpose - no intentional delay) fuses are UL class "K5" (up to and including 60 amps), and UL class "H" ( 65 amps
and above). See UL 248.
4 Maximum total length of copper supply conductors in entire installation, raceway and/or flexible cord.
5 Raceway conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment
per NEC Table 310.16 and is based on allowable ampacities of insulated copper conductors having a temperature rating of 75°C (167°F) with
not more than three single current-carrying conductors in a raceway.
6 Flexible cord conductor size is based on NEC Table 400.5(A)(1) for SOOW 600V 90°C (194°F) jacketed cable in a 30°C (86°F) ambient tem­perature. See NEC Table 310.15(B)(1)(1) for ambient temperature correction factors. Flexible cord used for connection to the power supply sys­tem shall comply with the requirements of UL 62.

(A)

1max

(A) 12

1eff

1

A 15 or 20 ampere in-

dividual branch cir-

4

cuit protected by

time-delay fuses or

circuit breaker is re-

2)5

2)5

2)6

quired. See Section

6-5.

26

35
40

51 (16)

14 (2.5)
14 (2.5)

14 (2.5)

6-4. Input Power Extension Cord Data

Use extension cord only for temporary wiring. Remove extension cord immediately after completing the project.

Cord Type Minimum Conductor Size Number Of Conductors Maximum Cord Length

Heavy Duty (Hard Usage) 12 AWG (4 mm

Read OSHA Standard 1910.334 for more information on the use of cord and plug connected equipment.

F

Read National Electrical Code (NEC) Article 590 for more information on temporary wiring.

2

) 3 50 ft (15 m)

OM-284208 Page 28

Complete Parts List is available at www.MillerWelds.com



A complete Parts List is available at www.MillerWelds.com

1

3

2

F

6-5. Connecting 120 Volt Input Power

Installation must meet all National
and Local Codes —have only quali­fied persons make this installation.

NOTICE – The Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied, either 120 or
240 VAC.

See rating label on unit and check input volt­age available at site.

For 120 volts AC input power, a 15 or 20 am­pere individual branch circuit protected by
time-delay fuses or circuit breaker is
required.

1 Multi-Voltage Plug And Power Cord Con-

nector (NEMA Type 5-15P Plug Shown)

For multi-voltage plug connections, see Sec­tion 6-2.

2 Plug From Unit

3 Receptacle - NEMA Type 5-15R (Cus-

tomer Supplied)

Disconnect cord from 240V receptacle in­side power switch box. Change MVP plug to
120 volts.

For weld output terminals and select-

F

ing cable sizes, see Section 5-7 and 5-

8.

OM-284208 Page 29

Complete Parts List is available at www.MillerWelds.com



A complete Parts List is available at www.MillerWelds.com

L1

L2

240 VAC, 1

8

2

1

L1

L2

1

=GND/PE Earth Ground

6

5

3

4

7

NGO’s

tools/

F

6-6. Connecting 1-Phase Input Power

Installation must meet all National
and Local Codes—have only quali­fied persons make this installation.

Disconnect and lockout/tagout in­put power before connecting input
conductors from unit. Follow es­tablished procedures regarding
the installation and removal of
lockout/tagout devices.

Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.

NOTICE – The Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied, either 120 or
240 VAC.

See rating label on unit and check input volt­age available at site.

Disconnect cord from 240 receptacle inside
power switch box.

1 Input Power Cord

2 Disconnect Device (switch shown in the

OFF position)

3 Disconnect Device Grounding Terminal

4 Disconnect Device Line Terminals

5 Black And White Input Conductor (L1

And L2)

6 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.

Connect input conductors L1 and L2 to dis­connect device line terminals.

7 Over-Current Protection

Select type and size of over-current protec­tion using Electrical Service Guide (fused
disconnect switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout proce­dures to put unit in service.

For weld output terminals and selecting

F

cable sizes, see Section 5-7 and 5-8.

OM-284208 Page 30

F

SECTION 7 – OPERATION

7-1. Front Panel Controls

Complete Parts List is available at www.MillerWelds.com

1 Engine Control Switch

Use switch to start engine and stop engine.
In Run position, engine runs at weld/power
speed.

2 Choke Control

Changes fuel/air mixture.

To Start:

l Open fuel valve (see Section 5-6).
l Pull out choke.
l Turn Engine Control switch to start posi-

tion and hold until engine starts.

l Slowly push in 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

F

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

3 Engine Hour Meter/Idle Control
4 Weld Output Control

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

5 Arc Control

When Arc Control is set at 0% (softest),
there is no added dig current. Weld output is
constant current based on the weld
command.

When Arc Control is set at 100% (stiffest),
the dig threshold is 19.5 volts, and the maxi­mum amount of dig current is added based
on the weld command setting. As the Arc
Control setting is reduced from 100%, the

dig threshold is lowered, resulting in less dig
current added and a softer arc.

6 Weld On/Off Switch

Use switch to turn on welder. Engine power
can be used with the weld power cable
plugged into generator or wall power.

7 Power Indicator LED

LED must be on to weld.

8 Overtemp/Fault Code LED

9 Supplementary Protector CB4

CB4 protects weld inverter when plugged in­to generator or utility power. If supplementa­ry protector opens, there will be no weld
output.

OM-284208 Page 31

Complete Parts List is available at www.MillerWelds.com

F

SECTION 8 – OPERATING AUXILIARY EQUIPMENT

8-1. Generator Power Panel Receptacles

Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCI­protected extension cord. Do not
use GFCI receptacles to power life
support equipment.

Unplug power cord before attempt­ing to service accessories or tools.

Generator power decreases as weld

F

current increases.

1 120 V Receptacles GFCI2 and GFCI3

GFCI2 and GFCI3 supply 60 Hz single­phase power at weld/power speed. See
Section 8-2 for testing and resetting
information.

2 Supplementary Protectors CB2 and CB3

CB2 protects GFCI2 and CB3 protects
GFCI3 from overload. If a supplementary
protector opens, the receptacle does not
work.

Press button to reset supplementary

F

protector. If supplementary protector
continues to open, contact Factory Au­thorized Service Agent.

Test GFCI monthly. See Section 8-2
for GFCI information and for reset­ting and testing procedures.

3 240 V Receptacle RC1

RC1 supplies 60 Hz single-phase power at
weld/power speed.

4 Supplementary Protector CB1

CB1 protects receptacles RC1, GFCI2, and
GFCI3 from overload. If CB1 opens, the re­ceptacles do not work. Place switch in On
position to reset.

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

OM-284208 Page 32

Complete Parts List is available at www.MillerWelds.com

1

2

3

4

5

6

F

8-2. GFCI Receptacle Information, Resetting, And Testing

Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCI­protected extension cord. Do not
use GFCI receptacle to power life
support equipment.

Unplug power cord before attempt­ing to service accessories or tools.

1 120 V 20 A AC GFCI Receptacle
2 GFCI Receptacle Test Button
3 GFCI Receptacle Reset Button
4 Red GFCI Indicator Light (LED)
5 Green GFCI Indicator Light (LED)
6 Alternate Location For Red And Green

Indicator LEDs

Red and Green indicator lights may be

F

combined in a single LED.

Orientation of receptacle may be differ-

F

ent in other applications.

GFCI Receptacles

GFCI receptacles protect the user from elec­tric shock if a ground fault occurs in equip­ment connected to the receptacle. A ground
fault occurs when electrical current takes
the shortest path to ground (which could be
through a person) rather than follow its in­tended safe path.

If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to dis­connect power to the faulty equipment. A
GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.

A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.

Resetting/Testing GFCI Receptacle

Test GFCI monthly.

If Red LED blinks, stop using GFCI
receptacle and have a Factory Au­thorized Service Agent replace it.

Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.

Resetting GFCI Receptacles

If a GFCI fault occurs, stop engine and dis­connect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place engine control switch in
RUN position, and press GFCI Reset button.
Reconnect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.

Testing GFCI Receptacles

Start engine and place engine control switch
in Run position. Press the GFCI Test button.
The GFCI Reset button should pop out.

Press the GFCI Reset button.

Have a Factory Authorized Service Agent
replace GFCI if any of the following
occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.

OM-284208 Page 33

Complete Parts List is available at www.MillerWelds.com

.



Complete Parts List available at www.MillerWelds.com

SECTION 8 MAINTENANCE

! Stop engine before maintaining.



See Engine Manual and Maintenance Label

Recycle engine

for important start-up, service, and storage

fluids.

information.

Service engine more often if

used in severe conditions.

Engine
Manual

Hours

 Oil Level Every 8 Hours  Oil, Fuel Spills Every 8

Hours

Engine
Manual,
Section 8-3,
8-4, 8-5

Complete Parts List is available at www.MillerWelds.com

1/2

in.

(13 mm)

SLUDGE

FUEL

Service engine more often if

Engine
Manual

Engine
Manual,
Section 8-3,
8-4, 8-5

F

SECTION 9 – MAINTENANCE

9-1. Routine Maintenance

Stop engine before maintaining.

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

F

severe conditions.

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

F

Recycle engine fluids.

F

ü = Check ◇ = Change m = Clean ¶ = Replace Reference

Engine
Manual

ü Fuel Level Every 8
Hours

Every

50

Hours

m Weld Terminals

Every

100

Hours

Every

200

Hours

Every

500

Hours

*To be done by factory authorized service agent.

ü¶ Air Filter Element m Cooling System ¶ Fuel Filter ◇ Oil

¶ Unreadable Labels m Battery Terminals ü¶ Weld Cables

ü Spark Plug Gap (0.030

in.)

ü Oil Level Every 8 Hours m Oil, Fuel Spills Every 8

ü m Slip Rings*
ü¶ Brushes*

Hours

ü Valve Clearance ¶ Air Cleaner Element

Engine
Manual,
Sections
9-3, 9-4, 9-5

Engine
Manual,

Engine
Manual
Section 9-3

OM-284208 Page 34

9-2. Maintenance Label

267206-F

Complete Parts List is available at www.MillerWelds.com

F

OM-284208 Page 35

F

 Complete Parts List available at www.MillerWelds.com

! Stop engine. Let cool

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

1 Screw
2 Foam Element
Inspect foam element. If element is

damaged, replace. If element is
clogged, wash foam element with
soap and water solution. Allow to air
dry completely.

 Do not wring out foam element,

this could cause it to tear.

Oil foam element using clean en-
gine oil. Squeeze out excess oil.
The engine will smoke if excess oil
remains.

2

1

! Stop engine. Let cool

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

1 Screw
2 Foam Element
Inspect foam element. If element is

damaged, replace. If element is
clogged, wash foam element with
soap and water solution. Allow to air
dry completely.



Do not wring out foam element,
this could cause it to tear.

Oil foam element using clean en-
gine oil. Squeeze out excess oil.
The engine will smoke if excess oil
remains.

2

1

Kohler 17 690 01 Rev E

! Stop engine. Close fuel

valve. 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
filter. Replace filter . Ensure flow ar-
row points towards carburetor.

allen_wrench

NGO’s

tools/

flathead philips head wrench

allen_set

crescent wrench

9-3. Servicing Air Cleaner

Complete Parts List is available at www.MillerWelds.com

NOTICE – Do not run engine without air
cleaner element or with dirty element.

1 Screw

2 Foam Element

Inspect foam element. If element is dam­aged, replace. If element is clogged, wash
foam element with soap and water solution.
Allow to air dry completely.

F

Oil foam element using clean engine oil.
Squeeze out excess oil. The engine will
smoke if excess oil remains.

Stop engine. Let cool.

Do not wring out foam element, this

could cause it to tear.

9-4. Changing Fuel Filter

Stop engine. Close fuel valve. Let
cool.

After servicing, start engine and
check for fuel leaks. Stop engine,
close fuel valve, tighten connec­tions as necessary, and wipe up
spilled fuel.

1 Fuel Filter

Locate fuel filter below fuel tank. Release
hose clamps and remove filter. Replace filter.
Ensure flow arrow points towards carburetor.

OM-284208 Page 36

Complete Parts List is available at www.MillerWelds.com



Complete Parts List available at www.MillerWelds.com

Kohler 17 690 01 Rev E

! Stop engine. Let cool

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

1 Screw
2 Foam Element
Inspect foam element. If element is

damaged, replace. If element is
clogged, wash foam element with
soap and water solution. Allow to air
dry completely.



Do not wring out foam element,
this could cause it to tear.

Oil foam element using clean en-
gine oil. Squeeze out excess oil.
The engine will smoke if excess oil
remains.

2

1

804 081-B

! Stop engine. Close fuel

valve. 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
filter. Replace filter . Ensure flow ar-
row points towards carburetor.

1



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/

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 with proper amount
and viscosity of oil according to
maintenance

label in Section 8-2.

Reinstall oil fill/check plug.

1

1

2

2

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers

knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose

steelbrush nutdriver

chippinghammer

solderiron

stripcrimp

torque screwdriver

crescent wrench

F

9-5. Changing Oil

Change oil while engine is warm. Make

F

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/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 with proper amount and vis­cosity of oil according to maintenance label.

Reinstall oil fill/check plug.

OM-284208 Page 37

Complete Parts List is available at www.MillerWelds.com

NGO’s

tools/

f

lathead

p

hilips head

w

rench

k

nife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

a

llen_set

s

teelbrush

n

utdriver

chippinghammer

crescent wrench

F

9-6. Adjusting Engine Speed

T25 Torx

After tuning engine, check engine speed.
See engine maintenance label for proper no
load speed. If necessary, unplug/remove all
loads and adjust speed as follows:

Start engine and run until warm.

Set Weld Output Control to Max.

Weld/Power Speed Adjustment

No. 2 Phillips

1 Adjustment Screw

Turn Engine Control switch to the Run posi­tion. Set speed to 3750 RPM. To increase
speed, turn screw in (clockwise). To de­crease speed, turn screw out
(counterclockwise).

Idle Speed Adjustment

2 Adjustment Screw

Turn Engine Control switch to the Run/Idle
position. Set speed to 2500 RPM. Use ad­justment screw to fine tune idle speed.

Stop engine. Close fuel valve.

OM-284208 Page 38

Complete Parts List is available at www.MillerWelds.com

 A complete Parts List is available at www.MillerWelds.com

907720

1 2 3

F

9-7. Reorienting Recoil Starter

Removing Recoil Starter

1 Recoil Starter

2 Screws

3 Blower Housing

Remove screws securing starter to blower
housing. Remove starter assembly.

Orient starter in desired position.

Installing Starter

Install retractable starter onto blower hous­ing, leaving screws slightly loose.

Pull starter handle out until pawls engage in
drive cup. Hold handle in this position and
tighten screws securely.

8 mm

OM-284208 Page 39

Complete Parts List is available at www.MillerWelds.com

F

SECTION 10 – TROUBLESHOOTING

10-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output or generator power
output at AC receptacles; fan does not
run; no power light.

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

No weld output; fan motor continues to
run.

Low weld output. Check Weld Output control setting.

High weld output. Check Weld Output control setting.

Erratic weld output. Check Weld Output control setting.

Ensure power cord is securely connected to 240V receptacle inside power shift box (if using genera­tor power).

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

Have Factory Authorized Service Agent flash the rotor. Then check brushes, slip rings, rotor, stator,
and PC3.

Secure power cord plug in receptacle (if using utility power) (see Section 6-2).

Replace building line fuse or reset circuit breaker if open.

Place Power switch in On position (see Section 7-1).

Reset welding power source supplementary protector if open (see Section 8-1).

Check Weld Output control setting (On/Off switch).

Ensure power cord is securely connected to 240V receptacle inside power shift box (if using genera­tor power).

Connect work clamp to get good metal to metal contact.

Check for loose connections.

Check for proper polarity connections (see Section 5-7).

Thermostat TP1 open (overheating). Allow fan to run; thermostat closes when unit has cooled.

Check engine speed, and adjust if necessary (see Section 9-6).

Service engine air cleaner (see Section 9-3). Service engine fuel filter (see Section 9-4).

Check weld cable size and length.

Connect unit to proper input voltage or check for low line voltage.

Place Power switch in On position (see Section 7-1).

Check engine speed, and adjust if necessary (see Section 9-6).

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 welder/generator.

Check engine speed, and adjust if necessary (see Section 9-6).

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

Service engine air cleaner (see Section 9-3). Service engine fuel filter (see Section 9-4).

B. Error Messages

Message Error Remedy

Overtemp LED is on steady. Internal temperature of welder has exceeded the

maximum limit.

Overtemp LED blinks 2 times. Primary voltage is above 310 volts. Reduce primary voltage below 310 volts.

Overtemp LED blinks 3 times. The primary voltage is below 90 volts. Increase primary voltage above 90 volts.

Overtemp LED blinks 4 times. The fan blades are obstructed. Clear obstruction from fan.

The fan wiring harness is disconnected. Reconnect the fan.

OM-284208 Page 40

Wait for unit to cool down. If the fan is not run­ning, contact Miller Electric Mfg. LLC service
department.

Complete Parts List is available at www.MillerWelds.com

F

Message Error Remedy

The fan is damaged. Contact Miller Electric Mfg. LLC service

The control board is damaged.

Overtemp LED blinks 5 times. The primary circuit thermistor is unplugged. Reconnect the primary circuit thermistor.

The primary circuit thermistor is reading too high
or too low for a valid temperature.

The control board is damaged.

Overtemp LED blinks 6 times. The secondary circuit thermistor is unplugged. Reconnect the secondary circuit thermistor.

The secondary circuit thermistor is reading too
high or too low for a valid temperature.

The control board is damaged.

Overtemp LED blinks 7 times. Input power failure. Check input power. Input voltage must be above

Overtemp LED blinks 8 times. The primary boost has not successfully been

established.

Overtemp LED blinks 9 times. The two microcontrollers on the control board

are no longer communicating.

department.

Contact Miller Electric Mfg. LLC service
department.

Contact Miller Electric Mfg. LLC service
department.

90 volts.

Cycle power to clear error. If this error persists
after a power cycle, contact Miller Electric Mfg.
LLC service department.

Cycle power to clear error. If this error persists
after a power cycle, contact Miller Electric Mfg.
LLC service department.

C. 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.

Low output at generator power AC
receptacles.

Erratic output at generator power AC
receptacles.

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

Have Factory Authorized Service Agent flash the rotor. Then check brushes, slip rings, rotor, stator,
and PC3.

Reset and check supplementary protector (see Section 8-1). Reset and check GFCI receptacle (see
Section 8-2).

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 9-6).

Check engine speed, and adjust if necessary (see Section 9-6). 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 9-4).

Check engine speed, and adjust if necessary (see Section 9-6).

D. Engine

Trouble Remedy

Engine will not crank. Check and replace ignition fuse F1.

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start or runs poorly. Check fuel level (see Section 5-6). Check and replace fuel filter if necessary (see Section 9-4).

Move choke control to correct position (see Section 7-1).

Open fuel valve (see Section 5-6). 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 spark plug. Clean and re-gap or replace if necessary.

Check oil level (see Section 5-6). Engine stops if oil level is too low. Refill crankcase with proper vis­cosity oil for operating temperature.

OM-284208 Page 41

Complete Parts List is available at www.MillerWelds.com

F

Trouble Remedy

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 9-6). Check throttle/governor linkage for

Check fuel level (see Section 5-6).

Open fuel valve (see Section 5-6). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.

Check oil level (see Section 5-6). Engine stops if oil level is too low.

Periodically recharge battery (approximately every 3 months). Replace battery if necessary.

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

smooth, non-binding operation.

Check and replace fuel filter if necessary (see Section 9-4).

Tune-up engine according to engine manual.

OM-284208 Page 42

Complete Parts List is available at www.MillerWelds.com

F

SECTION 11 – PARTS LIST

11-1. Recommended Spare Parts

Item No. Dia. Mkgs. Part No. Description Quantity

268469 Tune-Up & Filter Kit, Kohler (CH440)
268467 Spark Plug, Kohler (CH440) 1
268468 Filter, Air (Kohler CH440) 1
246110 Filter, Fuel In-line .250 Kohler 75um 1

F1 021718 Fuse, Mintr GL 30 Amp 32 Volt 1

OM-284208 Page 43

SECTION 12 – ELECTRICAL DIAGRAMS

OM-284208 Page 44

Figure 12-1. Circuit Diagram For Welder/Generator

284210-A

OM-284208 Page 45

SECTION 13 – GENERATOR POWER GUIDELINES

2

3

1

1-1. Grounding Generator To Truck Or Trailer Frame

1

3

2

GND/PE

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

F

13-1. Selecting Equipment

1 Generator Power Receptacles – Neutral

Bonded To Frame

2 3-Prong Plug From Case Grounded

Equipment

OR

3 2-Prong Plug From Double Insulated

Equipment

Be sure equipment has double insu-

F

lated symbol and/or wording on it.

Do not use 2-prong plug unless
equipment is double insulated.

13-2. Grounding Generator to Truck or Trailer Frame

Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.

Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding
Generators.

Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
frame. Always connect a ground

1 Equipment Grounding Terminal (On

2 Grounding Cable (Not Supplied)

wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.

Front Panel)

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

F

vehicle frame by metal-to-metal
contact.

OM-284208 Page 46

13-3. Grounding When Supplying Building Systems

GND/PE

1 2

2

3

VOLTS 115

4.5
50/60

AMPS
Hz

1

2

3

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 electri-

F

cal codes.

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

Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Port­able And Vehicle Mounted Welding
Generators.

13-4. How Much Power Does Equipment Require?

1 Resistive Load

A light bulb is a resistive load and requires a
constant amount of power.

2 Non-Resistive Load

Equipment with a motor is a non-resistive
load and requires approximately six times
more power while starting the motor than
when running (see Section 13-8).

3 Rating Data

Rating shows volts and amperes, or watts re­quired to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 amperes at 115

volts, calculate its running power require­ment in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

Example 2: If three 200 watt flood lamps are
used with the drill from Example 1, add the
individual loads to calculate total load.

(3 x 200W) + 520 W = 1120 W

The total load applied by the three flood
lamps and drill is 1120 watts.

OM-284208 Page 47

13-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975
3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10,550 2850
3 HP 15,900 3900
5 HP 23,300 6800

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

5 HP 23,300 6000

7-1/2 HP 35,000 8000

10 HP 46,700 10,700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

13-6. Approximate Power Requirements For Farm/Shop Equipment

Farm/Shop Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10,500 2800
Farm Duty Motors Std. (e.g. Con-

veyors, Feed Augers, Air
Compressors)

Farm Duty Motors High Tor­que (e.g. Barn Cleaners, Silo Un­loaders, Silo Hoists, Bunk
Feeders)

3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 Gal/Min 550 PSI 4500 1400

Shallow Well Pump 1/3 HP 2150 750

1/3 HP 1720 720
1/2 HP 2575 975
3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10,550 2850
3 HP 15,900 3900
5 HP 23,300 6800

1-1/2 HP 8100 2000

5 HP 23,300 6000

7-1/2 HP 35,000 8000

10 HP 46,700 10,700

700 PSI 6100 1600

1/2 HP 3100 1000

OM-284208 Page 48

13-7. Approximate Power Requirements For Contractor Equipment

Contractor Equipment Rating Starting Watts Running Watts

Hand Drill 1/4 in. 350 350

3/8 in. 400 400
1/2 in. 600 600

Circular Saw 6-1/2 in. 500 500

7-1/4 in. 900 900
8-1/4 in. 1400 1400

Table Saw 9 in. 4500 1500

10 in. 6300 1800
Band Saw 14 in. 2500 1100
Bench Grinder 6 in. 1720 720

8 in. 3900 1400

10 in. 5200 1600
Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10,500 2800

Electric Chain Saw 1-1/2 HP, 12 in. 1100 1100

2 HP, 14 in. 1100 1100

Electric Trimmer Standard 9 in. 350 350

Heavy Duty 12 in. 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in. 400 400
Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000
Submersible Pump 400 GPH 600 200
Centrifugal Pump 900 GPH 900 500
Floor Polisher 3/4 HP, 16 in. 4500 1400

1 HP, 20 in. 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-284208 Page 49

13-8. Power Required To Start Motor

VOLTS AMPS

HP

230 2.5

1/4

Hz
PHASE

CODE 60

1

M

AC MOTOR

1

2

3

4

1

2

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

Step 1: Find code and use table to find kVA/
HP. If code is not listed, multiply running am­perage by six to find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amperage (see

example).

Welder/generator amperage output must be
at least twice the motor’s running amperage.

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

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

Volts = 230, HP = 1/4, kVA/HP = 11.2

(11.2 x 1/4 x 1000) / 230 = 12.2A

Starting the motor requires 12.2 amperes.

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

13-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of Generator Output

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

2 5 Second Rule

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

OM-284208 Page 50

13-10. Typical Connections To Standby Power

1. Utility Electrical
Service

Have only qualified persons perform
these connections according to all
applicable codes and safety
practices.

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

Do not connect to any electrical dis­tribution system normally supplied
by utility power unless a proper
transfer switch and grounding pro­cedure are employed.

Customer-supplied equipment is re-

F

quired if generator will supply standby
power during emergencies or power
outages.

2. Transfer Switch 3. Fused Disconnect

5. Essential Loads

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)

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

Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-supplied) if
required by electrical code.

Switch (If Required)

4 Welder/Generator Output

Generator output voltage and wiring must
be consistent with regular (utility) system
voltage and wiring.

Connect generator with temporary or perma­nent wiring suitable for the installation.

Turn off or unplug all equipment connected
to generator before starting or stopping en­gine. When starting or stopping, the engine
has low speed which causes low voltage
and frequency.

5 Essential Loads

Generator output may not meet the electri­cal requirements of the premises. If genera­tor does not produce enough output to meet
all requirements, connect only essential
loads. See Section 13-4.

4. Welder/Generator
Output

OM-284208 Page 51

13-11. Selecting Extension Cord (Use Shortest Cord Possible)

A. Cord Lengths For 120 Volt Loads

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

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

Current

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

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.

2

)*

B. Cord Lengths For 240 Volt Loads

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

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

Current

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

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

7 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.

2

)*

OM-284208 Page 52

SECTION 14 – STICK WELDING (SMAW) GUIDELINES

crescent wrench

NGO’s

tools/

crescent wrench

1

4

3

5

2

7

6

14-1. Stick Welding Procedure

Tools Needed:

Equipment Needed:

Weld current starts when electrode
touches workpiece.

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 personal pro-

F

tective clothing.

1 Workpiece

Make sure workpiece is clean before
welding.

2 Work Clamp

Place as close to the weld as possible.

3 Electrode

Before striking an arc, insert an electrode in
the electrode holder. A small diameter elec­trode requires less current than a large one.
Follow recommendations of the electrode
manufacturer when setting weld amperage
(see Section 14-2).

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.
Correct arc length is related to electrode di­ameter. Examine the weld bead to determine
if the arc length is correct.

Arc length for 1/16 and 3/32 in. diameter
electrodes should be about 1/16 in. (1.6
mm); arc length for 1/8 and 5/32 in. electro­des should be about 1/8 in. (3 mm).

7 Slag

Use a chipping hammer and wire brush to re­move slag. Remove slag and check weld
bead before making another weld pass.

OM-284208 Page 53

14-2. Electrode And Amperage Selection Chart

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

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

50

100

150

200

250

300

350

400

450

ELECTRODE

DC*

AC

POSITION

PENETRATION

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

DEEP
DEEP

LOW
MED

LOW
LOW

LOW

ALL
ALL
ALL

ALL
ALL

FLAT

HORIZ*

ALL
ALL

EP
EP

EP,EN
EP,EN

EP

EP,EN

EP
EP

6010
6011
6013

7014
7018

7024

NI-CL

308L

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

ELECTRODE

AMPERAGE

RANGE

DIAMETER

MED

1

2

3

1

3

2

14-3. Striking An Arc

OM-284208 Page 54

Weld current starts when electrode
touches workpiece.

1 Electrode

2 Workpiece

3 Arc

Scratch Technique

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

Tapping Technique

Bring electrode straight down to 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.

14-4. Positioning Electrode Holder

90

°

90

°

10°-30°

1

2

90

°

90

°

10°-30

°

45

°

45

°

10°-30

°

1

1

2

2

3

1

2

5

423

1

2

3

1

4

5

Groove Welds

Fillet Welds

1 End View Of Work Angle

2 Side View Of Electrode Angle

After learning to start and hold an arc, prac­tice running beads of weld metal on flat
plates using a full electrode.

Hold the electrode nearly perpendicular to
the work, although tilting it ahead (in the di­rection of travel) will be helpful.

To produce the best results, hold a

F

short arc, travel at a uniform speed,
and feed the electrode downward at a
constant rate as it melts.

14-5. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

14-6. Good Weld Bead Characteristics

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.

4 No Overlap

5 Good Penetration into Base Metal

OM-284208 Page 55

14-7. Conditions That Affect Weld Bead Shape

10

° - 30°

1

2

3

4

10

° - 30°

1

2

3

4

5

6

7

8

10

° - 30°

1

2

3

4

5

6

7

8

9

10

11

3

1

2

Electrode Angle

Arc Length

Travel Speed

Weld bead shape is affected by elec-

F

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

1 Angle Too Small

2 Correct Angle

3 Drag

4 Angle Too Large

5 Too Short

6 Normal

7 Too Long

8 Spatter

9 Slow

10 Normal

11 Fast

14-8. Electrode Movement During Welding

Normally, a single stringer bead is sat-

F

isfactory for most narrow groove weld
joints; however, for wide groove weld
joints or bridging across gaps, a weave
bead or multiple stringer beads works
better.

1 Stringer Bead - Steady Movement Along

Seam

2 Weave Bead - Side To Side Movement

OM-284208 Page 56

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.

14-9. Welding Lap Joints

≤ 30

°

≤ 30

°

1

1

2

3

≤ 30

°

≤ 30

°

1

1

2

3

30

°

2

1

1/16 in.

(1.6 mm)

3

4

14-10. Welding Groove (Butt) Joints

1 Electrode

2 Single-Layer Fillet Weld

Move electrode in circular motion.

3 Multi-Layer Fillet Weld

Weld a second layer when a heavier fillet is
needed. Remove slag before making anoth­er weld pass. Weld both sides of joint for
maximum strength.

1 Tack Welds

Prevent butt joint distortion by tack welding
the materials in position before final weld.

Workpiece distortion occurs when heat is ap­plied locally to a joint. One side of a metal
plate will curl up toward the weld. Distortion
will also cause the edges of a butt joint to pull
together ahead of the electrode as the weld
cools.

2 Square Groove Weld

3 Single V-Groove Weld

4 Double V-Groove Weld

Materials up to 3/16 in. (5 mm) thick can
often be welded without special preparation
using the square groove weld. However,
when welding thicker materials it may be
necessary to prepare the edges (V-groove)
of butt joints to ensure good welds.

The single or double V-groove weld is good
for materials 3/16 - 3/4 in. (5-19 mm) thick.
Generally, the single V-groove is used on
materials up to 3/4 in. (19 mm) thick and
when, regardless of thickness, you can weld
from one side only. Create a 30 degree bevel
with oxyacetylene or plasma cutting equip­ment. Remove scale from material after cut­ting. A grinder can also be used to prepare
bevels.

OM-284208 Page 57

14-11. Welding T-Joints

≤ 30

°

≤ 30

°

1

1

2

3

30

°

2

1

1/16 in.

(1.6 mm)

3

4

≤ 45

°

1

2

1

3

2

≤ 30

°

≤ 30

°

1

1

2

3

30

°

2

1

1/16 in.

(1.6 mm)

3

4

≤ 45°

1

2

1

3

2

2 3 in.

1/4 in.

3

2
1

2 3 in.

3

2

1

(51-76 mm)

(6.4 mm)

(51-76 mm)

1 Electrode

2 Fillet Weld

Keep arc short and move at definite 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.

3 Multi-Layer Deposits

Weld a second layer when a heavier fillet is
needed. Use any of the weaving patterns
shown in Section 14-8. Remove slag before
making another weld pass.

14-12. Weld Test

1 Vise

2 Weld Joint

3 Hammer

Strike the weld joint in the direction shown. A
good weld bends over but does not break.

If the weld breaks, examine it to determine
the cause.

If the weld is porous (many holes), the arc
length was probably too long.

If the weld contains bits of slag, the arc may
have been too long or the electrode was
moved incorrectly which allowed molten slag
to be trapped in the weld. This may happen
on a V-groove joint made in several layers
and calls for additional cleaning between
layers.

If the original beveled surface is visible the
material was not fully melted which is often
caused by insufficient heat or too fast a trav­el speed.

14-13. Troubleshooting

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

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

OM-284208 Page 58

welding.

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

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.

Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceding
weld bead.

Possible Causes Corrective Actions

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

welding.

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

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.

Reduce travel speed.

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

Possible Causes Corrective Actions

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

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.

OM-284208 Page 59

Distortion - contraction of weld metal during welding that forces base metal to move.
Illustration: 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-284208 Page 60

Notes

Notes

Effective January 1, 2023 (Equipment with a serial number preface of ND or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war-

ranties expressed or implied.

LIMITED WARRANTY - Subject to the terms and
conditions below, Miller Electric Mfg. LLC, Apple­ton, Wisconsin, warrants to authorized distributors
that new Miller equipment sold after the effective
date of this limited warranty is free of defects in
material and workmanship at the time it is shipped
by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will
repair or replace any warranted parts or compo­nents that fail due to such defects in material or
workmanship. 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. Notifica­tions submitted as online warranty claims must
provide detailed descriptions of the fault and trou­bleshooting steps taken to diagnose failed parts.
Warranty claims that lack the required information
as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.

Miller shall honor warranty claims on warranted
equipment listed below in the event of a defect
within the warranty coverage time periods listed
below. Warranty time periods start on the delivery
date of the equipment to the end-user purchaser,
or 12 months after the equipment is shipped to a
US or Canada distributor, or 18 months after the
equipment is shipped to an international distributor,
whichever occurs first.

1 5 Years Parts — 3 Years Labor

l Original Main Power Rectifiers Only to Include

SCRs, Diodes, and Discrete Rectifier Modules
in non-inverter products

2 4 Years Parts (No Labor)

l Auto-Darkening ClearLight 2.0 Helmet Lenses

3 3 Years — Parts and Labor Unless Specified

l Auto-Darkening Helmet Lenses (No Labor)
l Engine Driven Welder/Generators (Including

EnPak) (NOTE: Engines are Warranted
Separately by the Engine Manufacturer.)

l Insight Welding Intelligence Products (Except

External Sensors)

l Inverter Power Sources
l Plasma Arc Cutting Power Sources
l Process Controllers
l Semi-Automatic and Automatic Wire Feeders
l Transformer/Rectifier Power Sources

4 2 Years — Parts and Labor

l Auto-Darkening Weld Masks (No Labor)
l Fume Extractors - Filtair 215, Capture 5, and

Industrial Collector Series

5 1 Year — Parts and Labor Unless Specified

l ArcReach Heater
l AugmentedArc, LiveArc, and MobileArc Weld-

ing Systems

l Automatic Motion Devices
l Bernard BTB Air-Cooled MIG Guns (No

Labor)

l CoolBelt, PAPR Blower, and PAPR Face

Shield (No Labor)

l Desiccant Air Dryer System
l Field Options (NOTE: Field options are cov-

ered for the remaining warranty period of
the product they are installed in, or for a
minimum of one year — whichever is
greater.)

l RFCS Foot Controls (Except RFCS-RJ45)
l Fume Extractors - Filtair 130, MWX and SWX

Series, ZoneFlow Extraction Arms and Motor
Control Box

l HF Units
l ICE/XT Plasma Cutting Torches (No Labor)
l Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)

l Insight Sensors
l Load Banks
l Motor-Driven Guns (except Spoolmate

Spoolguns)

l Positioners and Controllers
l Racks (For Housing Multiple Power Sources)
l Running Gear/Trailers
l Subarc Wire Drive Assemblies
l Supplied Air Respirator (SAR) Boxes and

Panels

l TIG Torches (No Labor)
l Tregaskiss Guns (No Labor)
l Water Cooling Systems
l Wireless Remote Foot/Hand Controls and

Receivers

l Work Stations/Weld Tables (No Labor)

6 6 Months — Parts

l 12 Volt Automotive-Style Batteries

7 90 Days — Parts

l Accessories (Kits)
l ArcReach Heater Quick Wrap and Air Cooled

Cables

l Canvas Covers
l Induction Heating Coils and Blankets, Cables,

and Non-Electronic Controls

l MDX Series MIG Guns
l M-Guns
l MIG Guns, Subarc (SAW) Torches, and Exter-

nal Cladding Heads

l Remote Controls and RFCS-RJ45
l Replacement Parts (No labor)
l Spoolmate Spoolguns

Miller’s True Blue
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

®

Limited Warranty shall not apply

improperly installed, improperly operated or
misused based upon industry standards, or
equipment which has not had reasonable and
necessary maintenance, or equipment which
has been used for operation outside of the
specifications for the equipment.

4. Defects caused by accident, unauthorized re­pair, or improper testing.

MILLER PRODUCTS ARE INTENDED FOR
COMMERCIAL AND INDUSTRIAL USERS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at
Miller’s option, either: (1) repair; or (2) replace­ment; or, if approved in writing by Miller, (3) the
pre-approved cost of repair or replacement at an
authorized Miller service station; or (4) payment of
or credit for the purchase price (less reasonable
depreciation based upon use). Products may not
be returned without Miller’s written approval. Re­turn shipment shall be at customer’s risk and
expense.

The above remedies are F.O. B. Appleton, WI, or
Miller’s authorized service facility. Transportation
and freight are the customer’s responsibility. TO
THE EXTENT PERMITTED BY LAW, THE REM­EDIES HEREIN ARE THE SOLE AND EXCLU­SIVE REMEDIES REGARDLESS OF THE LEGAL
THEORY. IN NO EVENT SHALL MILLER BE LI­ABLE FOR DIRECT, INDIRECT, SPECIAL, INCI­DENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS
OF THE LEGAL THEORY. ANY WARRANTY NOT
PROVIDED HEREIN AND ANY IMPLIED WAR­RANTY, GUARANTY, OR REPRESENTATION, IN­CLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTIC­ULAR PURPOSE, ARE EXCLUDED AND DIS­CLAIMED BY MILLER.

Some US states do not allow limiting the duration
of an implied warranty or the exclusion of certain
damages, so the above limitations may not apply
to you. This warranty provides specific legal rights,
and other rights may be available depending on
your state. In Canada, some provinces provide ad­ditional warranties or remedies, and to the extent
the law prohibits their waiver, the limitations set out
above may not apply. This Limited Warranty pro­vides specific legal rights, and other rights may be
available, but may vary by province.

Warranty Questions?

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

Your distributor also gives you...

Service

You always get the fast, reliable response you
need. Most replacement parts can be in your
hands in 24 hours.

Support

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

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date

Distributor

Address

City

State Zip

(Date which equipment was delivered to original customer.)

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Protective Equipment (PPE)

Contact the Delivering Carrier to:

Service and Repair Replacement Parts

Training (Schools, Videos, Books)

Welding Process Handbooks

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, con­tact your distributor and/or equipment manu­facturer’s Transportation Department.

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone]
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS – PRINTED INUSA © Miller Electric Mfg. LLC 2023-05