Miller Trailblazer 325 User Manual

OM-277904A 2017−01

Processes

MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding

TIG (GTAW) Welding
Pulse TIG (GTAW) Welding

Air Plasma Cutting and Gouging
with Spectrum Unit

Air Carbon Arc (CAC-A) Cutting
and Gouging

Description

Engine Driven Welder/Generator



Trailblazer 325

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

File: Engine Drive

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 2009−09

TABLE OF CONTENTS

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

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

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

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

1-4. Compressed Air Hazards 3..............................................................

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

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

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

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

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 7..........................

2-1. Signification des symboles 7.............................................................

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

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

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

2-5. 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 14..................................................................

3-1. Additional Safety Symbols And Definitions 14................................................

3-2. Miscellaneous Symbol Definitions 14.......................................................

SECTION 4 − SPECIFICATIONS 15..............................................................

4-1. Serial Number And Rating Label Location 15................................................

4-2. Specifications 15........................................................................

4-3. Environmental Specifications 15...........................................................

4-4. Dimensions, Weights, And Operating Angles 16..............................................

4-5. Duty Cycle 17..........................................................................

4-6. Fuel Consumption Curves 18.............................................................

4-7. Stick Volt-Ampere Curves 19.............................................................

4-8. MIG Volt-Ampere Curves 20..............................................................

4-9. TIG Volt-Ampere Curves 20..............................................................

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

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

5-2. Grounding Generator To Truck Or Trailer Frame 22...........................................

5-3. Installing Exhaust Pipe 22................................................................

5-4. Engine Prestart Checks 23...............................................................

5-5. Connecting Or Replacing The Battery 24....................................................

5-6. Weld Output Terminals 25................................................................

5-7. Connecting To Weld Output Terminals 26...................................................

5-8. Selecting Weld Cable Sizes* 26...........................................................

5-9. Remote Receptacle Information 27.........................................................

SECTION 6 − OPERATING WELDER/GENERATOR 28.............................................

6-1. Front Panel Controls (See Section 6-2) 28..................................................

6-2. Description Of Front Panel Controls (See Section 6-1) 29......................................

6-3. Cold Weather Engine Operation 30........................................................

6-4. Process/Contactor Switch, Engine Auto Speed, And Arc Control 31.............................

6-5. Stick Start Procedure − Scratch Start Technique 34...........................................

6-6. Lift-Arc TIG With Auto-Crater And Auto-Stop 34.........................................

6-7. Remote Voltage/Amperage Control 35......................................................

TABLE OF CONTENTS

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 36............................................

7-1. Generator Power Receptacles And Supplementary Protectors 36...............................

7-2. GFCI Receptacle Information, Resetting And Testing 37.......................................

7-3. Optional Excel Power 38.................................................................

7-4. Simultaneous Weld And Power 38.........................................................

7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 39..................

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 40.........................................

8-1. Maintenance Label 40...................................................................

8-2. Routine Maintenance 41.................................................................

8-3. EFI System And Servicing Information 41...................................................

8-4. Servicing Air Cleaner 42.................................................................

8-5. Servicing Optional Spark Arrestor 42.......................................................

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter 43.............................................

8-7. Overload Protection 44..................................................................

8-8. Engine Speed Adjustment 44.............................................................

8-9. Welding Troubleshooting 45..............................................................

8-10. Generator Power Troubleshooting 46.......................................................

8-11. Engine Troubleshooting 46...............................................................

SECTION 9 − PARTS LIST 48...................................................................

9-1. Recommended Spare Parts 48............................................................

SECTION 10 − ELECTRICAL DIAGRAMS 50......................................................

SECTION 11 − GENERATOR POWER GUIDELINES 52.............................................

COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2015−09

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

1-1. Symbol Usage

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

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

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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

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

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

there is a danger of falling.

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

unit.

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

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

 Disconnect input power or stop engine before installing or

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

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

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

 Indicates special instructions.

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

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

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

 Frequently inspect input power cord and ground conductor for

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

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

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

 Use GFCI protection when operating auxiliary equipment. Do not

test or reset GFCI receptacles at idle speed/low voltage or the
GFCI will be damaged and not provide protection from electric
shock caused by a ground fault.

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

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

 Do not touch hot parts bare handed.
 Allow cooling period before working on

equipment.

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

lated welding gloves and clothing to prevent burns.

OM-277904 Page 1

FLYING METAL or DIRT can injure

e

.

eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side shields even under your

welding helmet.

FUMES AND GASES can be
hazardous.

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

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

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

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

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

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

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

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

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

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

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

BUILDUP OF GAS can injure or kill.

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

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

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

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

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

 Wear approved safety glasses with side shields under your

helmet.

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

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

 Wear body protection made from durable, flame-resistant material

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

WELDING can cause fire or explosion

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

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

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

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

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.

OM-277904 Page 2

workpiece, and hot equipment can cause fires and

 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

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

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

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

gas, or liquid vapors (such as gasoline).

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

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

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

contact tip when not in use.

 Wear body protection made from durable, flame-resistant material

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

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

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

 Wear approved ear protection if noise level is

high.

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

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should con­sult their doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
heating operations.

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

1-3. Engine Hazards

BATTERY EXPLOSION can injure.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

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

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

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

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

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

 Follow battery manufacturer’s instructions when working on or

near a battery.

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

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

MOVING PARTS can injure.

 Keep away from moving parts such as fans,

belts, and rotors.

 Keep all doors, panels, covers, and guards

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

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

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

EXHAUST SPARKS can cause fire.

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

required areas — see applicable codes.

HOT PARTS can burn.

 Do not touch hot parts bare handed.
 Allow cooling period before working on

equipment.

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

lated welding gloves and clothing to prevent burns.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine manual).

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

flow tank, follow the next two statements.

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

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can
injure or kill.

 Incorrect installation or operation of this unit

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

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

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

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

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

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

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

 Do not modify or alter compressor or manufacturer-supplied

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

 Use only components and accessories approved by the manufac-

turer.

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

equipment connected to the compressed air system.

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

by air pressure. Properly support equipment by mechanical
means.

OM-277904 Page 3

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

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

COMPRESSED AIR can injure or kill.

 Before working on compressed air system,

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

 Relieve pressure before disconnecting or con-

necting air lines.

 Check compressed air system components

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

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

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

 Use soapy water or an ultrasonic detector to search for

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

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

finished and before starting unit.

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

mediately.

MOVING PARTS can injure.

 Keep away from moving parts such as fans,

belts and rotors.

 Keep all doors, panels, covers, and guards

closed and securely in place.

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

parts.

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

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

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

enance and troubleshooting as necessary.

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

finished and before starting engine.

HOT PARTS can burn.

 Do not touch hot compressor or air system

parts.

 Allow cooling period before working on

equipment.

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

lated welding gloves and clothing to prevent burns.

BREATHING COMPRESSED AIR can in­jure or kill.

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

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.

 Release air pressure from tools and system be-

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

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

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

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

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

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

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

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

FALLING EQUIPMENT can injure.

 Use lifting eye to lift unit and properly installed

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

 Use equipment of adequate capacity to lift and support unit.
 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

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

when working from an aerial location.

 Follow the guidelines in the Applications Manual for the Revised

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

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

where applicable.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

FLYING SPARKS can injure.

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

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

MOVING PARTS can injure.

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

rolls.

OM-277904 Page 4

BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.

Battery charging not present on all models.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connecting battery cables,

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

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

less it has a battery charging feature designed for this purpose.

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

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

 Follow battery manufacturer’s instructions when working on or

near a battery.

 Have only qualified persons do battery charging work.
 If battery is being removed from a vehicle for charging, discon-

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

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

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

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

restricted.

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

damage such as a cracked case or cover.

 Before charging battery, select correct charger voltage to match

battery voltage.

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

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

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

parts.

HIGH PRESSURE FLUIDS can injure or kill.

 Engine fuel system components can be under

high pressure.

 Before working on fuel system, turn off engine

to release pressure.

 If any fluid is injected into the skin or body seek medical help im-

mediately.

WELDING WIRE can injure.

 Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

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

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can injure.

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

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

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

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

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

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

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

equipment at once.

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

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

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is electromagnetically

compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

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

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

OM-277904 Page 5

1-6. California Proposition 65 Warnings

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

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

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

1-7. Principal Safety Standards

For Gasoline Engines:

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

For Diesel Engines:

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

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

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

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

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

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

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: [phone],
website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

1-8. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

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.

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

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

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

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

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Indus-

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

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

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

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

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

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

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

About Implanted Medical Devices:

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

OM-277904 Page 6

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

fre_rom_2015−09

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

2-1. Signification des symboles

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

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

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

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

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.

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

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

UN CHOC ÉLECTRIQUE peut tuer.

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

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

tant pas de trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans

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

 Indique des instructions spécifiques.

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

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

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

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

1910.147 (voir normes de sécurité).

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

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

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

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

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

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

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

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

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

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

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

nés ou réparés.

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

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

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

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

 Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

 Ne pas toucher aux portes−électrodes qui sont raccordés à deux

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

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

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

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

contact avec tout objet métallique.

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

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

OM-277904 Page 7

 Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire. Ne pas tester ni réarmer les prises femelles
avec différentiel au régime de ralenti/en basse tension: cela
endommagerait le disjoncteur différentiel, qui ne remplirait plus
son rôle de protection contre une électrocution causée par un
défaut de masse.

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

 Couper l’alimentation du poste et décharger les condensateurs

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

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

 Ne pas toucher à mains nues les parties chau-

des.

 Prévoir une période de refroidissement avant

de travailler à l’équipement.

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

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

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

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

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

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

facial.

LES FUMÉES ET LES GAZ peu­vent être dangereux.

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

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

veau 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 auxquels est exposé le personnel.

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

approuvé.

 Lire et comprendre les fiches de données de sécurité et les instruc-

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

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

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

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

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

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

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

OM-277904 Page 8

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

 Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

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

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

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

Le rayonnement de l’arc du procédé de soudage

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

 Porter un casque de soudage approuvé muni de verres filtrants

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

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

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

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

 Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

des réservoirs, tambours, ou conduites, à moins qu ils n aient
été préparés correctement conformément à AWS F4.1 et AWS
A6.0 (voir les Normes de Sécurité).

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

 Lire et comprendre les fiches de données de sécurité et les instruc-

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

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les

oreilles si le niveau sonore est trop élevé.

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

 Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

 Les porteurs d’implants médicaux doivent consulter leur

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

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

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

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

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

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

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

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

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.

 Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

 Ne jamais souder une bouteille pressurisée − risque d’explosion.

 Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

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

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

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

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

d’utilisation ou de branchement de la bouteille.

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

samment de personnes pour soulever et déplacer les bouteilles.

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

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

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

 Toujours porter une protection faciale, des

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

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

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

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

la batterie.

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

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

 Observer la polarité correcte (+ et −) sur les batteries.

 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

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

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

 Respecter les consignes du fabricant de la batterie pour travailler

sur une batterie ou à proximité.

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

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

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

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

 Maintenir fermés et verrouillés les portes, panneaux,

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

LE CARBURANT MOTEUR peut pro-

voquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de

carburant ou de faire le plein.

les ou d’une flamme nue.

pour son expansion.

carburant renversé avant de faire démarrer le moteur.

remplissage.

Les PIÈCES MOBILES peuvent causer

des blessures.

 S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

recouvrements et dispositifs de protection.

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

OM-277904 Page 9

 Pour empêcher tout démarrage accidentel pendant les travaux

s

e

­r

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

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

des organes mobiles.

 Remettre en place les portes, panneaux, recouvrements ou

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

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

mise en route accidentelle du moteur.

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

intervention sur le générateur.

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

 Ne pas toucher des parties chaudes à main

nues.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

me suivant.

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

le bouchon du radiateur.

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

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN

QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

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

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

tes et fenêtres ouvertes.

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

bouches aération.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

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

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

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

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

proximité de surfaces inflammables.

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

2-4. Dangers liés à l’air comprimé

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

 Une installation ou une utilisation incorrecte de cet appareil

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

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

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

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

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

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

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

 Ne pas modifier ou altérer le compresseur ou les équipements

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

 Utiliser uniquement des composants et accessoires homologués

par le fabricant.

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

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

OM-277904 Page 10

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

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

MÉTAL CHAUD provenant du décou-

page ou du gougeage à l’arc risque de

provoquer un incendie ou une explo-

sion.

 Ne pas découper ou gouger à proximité de produits inflam-

mables.

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

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

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

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

 Détendre la pression avant de débrancher ou

de brancher des canalisations d’air.

 Avant d’utiliser l’appareil, contrôler les composants du circuit d’air

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

 Ne pas diriger un jet d’air vers soi−même ou vers autrui.
 Pour intervenir sur un circuit d’air comprimé, porter un équipement

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

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

e

-

-

,

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

 Remettre les portes, panneaux, recouvrements ou dispositifs

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

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

immédiatement une assistance médicale.

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

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

des organes mobiles.

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

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

 Demander seulement à un personnel qualifié d’enlever

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

 Remettre en place les portes, panneaux, recouvrements ou

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

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

découper ou gouger ainsi que pour l’outillage
pneumatique.

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

 Détendre la pression pneumatique des outils et

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

Les PIÈCES MOBILES peuvent causer
des blessures.

 S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

 Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs
de protection.

 Ne pas toucher aux pièces chaudes, utiliser les outils recom-

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

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

constructeur.

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

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

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

 Ne pas toucher de pièces chaudes

du compresseur ou du circuit d’air.

 Prévoir une période de refroidissement avant

d’intervenir sur l’équipement.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

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

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU
D’EXPLOSION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.

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

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

 Utiliser un équipement de levage de capacité suffisante pour

lever l’appareil.

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

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

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

mobiles lors de toute opération en hauteur.

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

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

LE SURCHAUFFEMENT peut

endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous risque d’en

dommager le moteur électrique à cause d’une tension et d’une fré
quence trop faibles.

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

s’il y a lieu.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

 Porter un écran facial pour protéger le visage et

les yeux.

 Affûter l’électrode au tungstène uniquement à

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

 Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

Les PIÈCES MOBILES peuvent

causer des blessures.

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

tels que des rouleaux de commande.

OM-277904 Page 11

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

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

 Toujours porter une protection faciale, des gants en caoutchouc

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

 Arrêter le moteur avant de débrancher ou de brancher des

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

 Eviter de provoquer des étincelles avec les outils en travaillant

sur la batterie.

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

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

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

dernier lieu.

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

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

 Respecter les consignes du fabricant de la batterie pour

travailler sur une batterie ou à proximité.

 Les opérations de charge de batterie ne doivent être effectuées

que par des personnes qualifiées.

 Pour enlever la batterie d’un véhicule pour la recharge,

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

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

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

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

l’absence d’une ventilation.

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

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

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

correspondant à la tension de la batterie.

 Régler les commandes de charge de batterie sur la position

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

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

des pièces mobiles du véhicule.

LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.

 Les composants du système d’alimentation

peuvent contenir du carburant sous pression
élevée.

 Avant d’intervenir sur le système d’alimentation de carburant,

arrêter le moteur pour dépressuriser le système.

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

solliciter une aide médicale sur le champ.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

OM-277904 Page 12

 Réduire le courant ou le facteur de marche avant de poursuivre le

soudage.

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

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut

provoquer des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

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

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

constructeur.

 Effectuer l’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 FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

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

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

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

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

qualifié les interférences résultant de l’installation.

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

pareil.

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

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

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

 L’énergie électromagnétique risque de provo-

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

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

patible électromagnétiquement.

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

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

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

électronique sensible.

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

conformément à ce mode d’emploi.

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

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

2-6. Proposition californienne 65 Avertissements

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

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

manipulation.

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

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

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

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

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

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: [phone],
website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Pour les moteurs à essence :

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

Pour les moteurs diesel :

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

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

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

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

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

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Indus-

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

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

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

2-8. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: par exemple, des restrictions
d’accès pour les passants ou une évaluation individuelle des risques
pour les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

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

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

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

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-277904 Page 13

 Complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

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.

Safe1 2012−05

Safe87 2012−07

Safe88 2012−07

3-2. Miscellaneous Symbol Definitions

A

V

Amperage

Voltage

Negative

Positive

Alternating

Current (AC)

Protective Earth

(Ground)

Air Filter

Engine RPM

Circuit Breaker
Supplementary

Protector

Direct Current

(DC)

Engine Choke

Temperature

Battery (Engine)

Read Operator’s

Manual

Engine Oil

Engine

Engine Start

Engine Stop

Fast

Hertz

U
U

I

X

Percent

Rated No−Load

0

2

2

Voltage (OCV)

Conventional
Load Voltage

242a Rated

Current

Duty Cycle

Lift Arc TIG

Shielded Metal

Arc Welding

(SMAW)

Gas Metal Arc

Welding (GMAW)

Gas Tungsten Arc
Welding (GTAW) /

Tungsten Inert

Gas (TIG)

Welding

Remote

OM-277904 Page 14

Fuel

Slow

Output

Single Phase

Alternator

On

 Complete Parts List is available at www.MillerWelds.com

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number for this product is located on the front. The rating information for this product is located on the back. Use rating label to determine
rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Specifications

 This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).

Welding

Mode

CC/DC

CV/DC

Rated

Welding

Output

325 A, 28 V, 100%

Duty Cycle

325 A, 28 V, 100%

Duty Cycle

Weld

Output

Range

10 − 325 A

13 − 35 V

4-3. Environmental Specifications

A. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

14 to 104°F (−10 to 40°C)

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

Notes

Maximum

Open-Circuit

Voltage

100 VDC

Generator

Power Rating

Peak: 12 kVA/kW

Continuous:

10.5 kVA/kW,

88/44 A, 120/240 V AC,

60 Hz, Single-Phase

Fuel

Capacity

12 gal
(45 L)

Tank

−4 to 131°F (−20 to 55°C)

Engine

Kohler CH730

Air-Cooled,

Two-Cylinder,

Four-Cycle,

23.5 HP Gasoline Engine
OR

Kohler ECH-730

Air-Cooled,

Two-Cylinder,

Four-Cycle,

23 HP Electronic Fuel

Injected Gasoline Engine

Temp_2016-07

OM-277904 Page 15

 Complete Parts List is available at www.MillerWelds.com

4-4. Dimensions, Weights, And Operating Angles

20°
20°

! Do not exceed tilt angles or engine

could be damaged or unit could tip.

! Do not move or operate unit where it

20°

20°

could tip.

Weight: 460 lb (209 kg) w/o fuel

533 lb (242 kg) w/fuel

Lifting Eye Weight Rating: 1280 lb (580 kg)

Support Assembly Dimensions

OM-277904 Page 16

Ref: 251 959-A

4-5. Duty Cycle

 Complete Parts List is available at www.MillerWelds.com

100%dutycycle

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

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

Continuous

Welding

277791-A

OM-277904 Page 17

 Complete Parts List is available at www.MillerWelds.com

4-6. Fuel Consumption Curves

Weld Fuel Consumption

2.00

On a typical job using 1/8 in. 7018
electrodes (125 amps, 20% duty
cycle), expect about 20 hours of op­eration with carbureted engine (24
hours with EFI engine).

Welding at 150 amps at 40% duty
cycle uses about 3/4 gallon of fuel
per hour. Expect about 16 hours of
operation with carbureted engine
(19 hours with EFI engine).

1.80

1.60

1.40

1.20

1.00

Run No-Load Carb

0.80

US GAL/HOUR

0.60

0.40

0.20

0

0

Weld Carb

Weld EFI

Run No-Load EFI
Idle Carb
Idle EFI

50 100 150 200 250 300 350

AMPERES

Auxiliary Power Fuel Consumption

2.50

2.00

1.50

1.00

US GAL/HOUR

0.50

0

0 2000 4000 6000 8000 10000 12000

OM-277904 Page 18

Aux Power Carb

Aux Power EFI

Run No-Load Carb

Run No-Load EFI
Idle Carb

Idle EFI

WATTS

254 853-A

 Complete Parts List is available at www.MillerWelds.com

4-7. Stick Volt-Ampere Curves

100

90

80

70

60

50

VOLTS

40

30

20

10

30 A  150 A Stiff 25150 A Soft 25

0

0 50 100 150 200 250 300 350

CC/DC XX10 Electrode

150 A  325 A 

AMPERES

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator.

400

450

CC/DC XX18 Electrode

100

90

80

70

60

50

VOLTS

40

30

20

10

30 A  150 A Stiff 25150 A Soft 25 150 A  325 A 

0

0 50 100 150 200 250 300 350

AMPERES

400

450

257 137

OM-277904 Page 19

 Complete Parts List is available at www.MillerWelds.com

4-8. MIG Volt-Ampere Curves

100

90

80

70

60

50

VOLTS

40

30

20

10

0

0 50 100 150 200 250 300 350

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator.

35 Volts

25 Volts

13 Volts

400

AMPERES

4-9. TIG Volt-Ampere Curves

100

90

80

70

60

50

VOLTS

40

30

20

10 Amps

10

0

0 50 100 150 200 250 300 350

257 137

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator.

325 Amps

150 Amps

AMPERES

OM-277904 Page 20

257 137

 Complete Parts List is available at www.MillerWelds.com

5

SECTION 5 − INSTALLATION

-1. Installing Welder/Generator

! Do not move or operate unit

where it could tip.

Movement

Location / Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

OR

OR

OR

18 in

(460 mm)

! Do not lift unit from end.
! Do not weld on base. Welding

on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.

! Always securely fasten weld-

ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica­ble codes.

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

 See Section 4-4 for lifting eye rat-

ing.

Mounting:

! Do not mount unit by support-

ing the base only at the four
mounting holes. Do not use
flexible mounts. Use cross­supports to adequately sup­port unit and prevent damage
to base.

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

 Go to MillerWelds.com for more

information on truck installations.

18 in

(460 mm)

Mounting

18 in

(460 mm)

1

install2 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712

OM-277904 Page 21

 Complete Parts List is available at www.MillerWelds.com

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

5-3. Installing Exhaust Pipe

1

GND/PE

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

2

3

! Use GFCI protection when operat-

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

rot_grnd2 2012−03 − 800 652-D

2 Equipment Grounding Terminal (On

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

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

 Electrically bond generator frame to ve-

hicle frame by metal-to-metal contact.

! Stop engine and let cool.
! Engine backfire can cause se-

vere burns or other injuries.
Do not point exhaust pipe to­ward control panel. Keep away
from exhaust outlet.

! Do not point exhaust pipe to-

ward LP fuel tank (if equipped).
Do not point exhaust pipe to­wards shielding gas tank (if
equipped).

! Point exhaust pipe in desired

direction but always away
from front panel and direction
of travel.

Tools Needed:

1/2 in.

OM-277904 Page 22

253 857-A

 Complete Parts List is available at www.MillerWelds.com

5-4. Engine Prestart Checks

Full

Empty

Expansion
Space

Full

Gasoline

Oil Fill

Oil Check

Full

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

 Follow run-in procedure in en-

gine manual.

 This unit has a low oil pressure

shutdown switch. However,
some conditions may cause en­gine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.

Fuel

Open left side access door.
Add fresh fuel before starting engine

the first time (see maintenance label
for specifications). Stop fueling when
fuel level reaches Max Fill Level on
tank. Do not top off tank. Always
leave room for expansion. Check
fuel level on a cold engine before use
each day.

To check fuel level, turn Engine Con­trol switch to Auto Speed position.
LEDs indicates fuel level in tank.

Close left side access door. Open
top service door.

Oil

 Do not exceed the ”Full” mark on

the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.

Check oil with unit on level surface.
If oil is not up to full mark on dipstick,
add oil (see maintenance label).

Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).

 To improve cold weather

starting:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.

Close top service door.

250 916−A

OM-277904 Page 23

 Complete Parts List is available at www.MillerWelds.com

5-5. Connecting Or Replacing The Battery

! Connect negative (−) battery

cable last

To connect battery, open side access
doors.

Do not allow the battery cables to
touch opposing terminals. When
connecting the battery cables at­tache the positive (+) battery terminal
first, followed by negative (−) battery
terminal.

Never start the engine when the ca­bles are loose or poorly connected to
the battery terminals.

Never disconnect the battery while
the engine is running.

Never use a quick battery charger to
start the engine.

Do not charge battery with Engine
Control switch On.

Always disconnect the negative (−)
battery cable before charging bat­tery.

1 Battery Holddown
To change battery, remove rear pan-

el with baffle and battery holddown.
Be sure battery cables and fuel tank

vent hose are not pinched when in­stalling battery and replacing rear
panel.

+

1

−

Tools Needed:

1/2, 3/8 in.

OM-277904 Page 24

250 916-A / Ref. S-0756-D

 Complete Parts List is available at www.MillerWelds.com

5-6. Weld Output Terminals

! Stop engine.
! Turn off power before con-

necting to weld output termi­nals.

! Do not use worn, damaged,

undersized, or repaired
cables.

1 Positive (+) Weld Output

Terminal

2 Stick Negative (−) Weld

Output Terminal

3 Wire/TIG/Gouge Negative (−)

Weld Output Terminal

For MIG welding, connect work
cable to Negative (−) terminal and
wire feeder cable to Positive (+)
terminal.

For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Positive
(+) terminal.

For TIG welding, connect work
cable to Positive (+) terminal and
electrode holder cable to Negative
(−) terminal.

1

3

2

249 855-E / 250 916-A

OM-277904 Page 25

 Complete Parts List is available at www.MillerWelds.com

5-7. Connecting To Weld Output Terminals

1

6

3

4

5

Tools Needed:

2

3/4 in.

! Stop engine.
! Failure to properly connect

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

 Do not place anything between

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

1 Correct Weld Cable

Connection

2 Incorrect Weld Cable

Connection
3 Weld Output Terminal
4 Supplied Weld Output

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

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

803 778-B

5-8. Selecting Weld Cable Sizes*

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

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

Not Exceeding***

100 ft (30 m) or Less

10 − 60%

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)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Duty

Cycle

AWG (mm2)

60 − 100%

Duty Cycle

AWG (mm2)

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 − 100% Duty Cycle

AWG (mm2)

350 ft

(105 m)

400 ft

(120 m)

Ref. S-0007-L 2015−02

OM-277904 Page 26

 Complete Parts List is available at www.MillerWelds.com

5-9. Remote Receptacle Information

AJ

K

B

L

C

D

*The remaining sockets are not used.

I

NH

M

G

F

E

Notes

24 VOLTS AC

REMOTE

OUTPUT

CONTROL

GND

Socket* Socket Information

A 24 volts ac. Protected by supplementary protector

CB4.

B Contact closure to A completes 24 volt AC con-

tactor control circuit and keeps engine at Run
speed in all Wire modes.

C +10 volts dc output to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control.

F Current feedback: 1 volt per 100 amperes.

H Voltage feedback: 1 volt per 10 arc volts.

G Circuit common for 24 volts AC circuits.

K Chassis common.

WELD JOINT
TYPES

GROOVE

FILLET

Ref. AWS/ANSI D1.1

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

BUTT

1G

T−JOINT

1F

BUTT

2G

T−JOINT

2F

BUTT

3G

T−JOINT

3F

T−JOINT

4F

OM-277904 Page 27

BUTT

4G

Ref. 804 248-A

 Complete Parts List is available at www.MillerWelds.com

SECTION 6 − OPERATING WELDER/GENERATOR

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

1

2

3

4

5

6

OM-277904 Page 28

9

8

7

248 009-A / 251 160-A

 Complete Parts List is available at www.MillerWelds.com

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

1 Process/Contactor Switch
See Section 6-4 for Process/Contactor

switch information.
2 And 3 Displays
Displays can show weld process information

(voltage and amperage) or maintenance in­formation (hourmeter, oil change count­down, or rpm).

Meter Weld Functions: In Wire modes, Volt­meter displays preset weld voltage when not
welding. Meters display actual voltage and
amperage when welding and for five sec­onds after welding has stopped.

In Stick and TIG modes, Voltmeter reads ON
and Ammeter displays preset amperage
when not welding. Meters display actual volt­age and amperage when welding and for five
seconds after welding has stopped.

Meter Engine Maintenance Functions:

See inset from maintenance label.
For oil change interval, if negative hours are

indicated, CHNG OIL appears on the dis­plays when the unit is started.

4 Voltage/Amperage Control
Use control to select weld voltage or

amperage. Control may be adjusted while
welding.

With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amper­age. With Process/Contactor switch in any

Wire position, use control to adjust voltage.
When a remote voltage/amperage control is
connected to Remote receptacle RC4, con­trol sets the maximum amperage in Stick and
TIG modes, but has no effect in MIG modes.

5 Arc Control
See Section 6-4 for Arc Control information.
Control is not functional when one of the fol-

lowing modes is selected:
TIG
Gouge
Flux-Core

6 Fuel Level Indicator
With Engine running or Engine Control

switch in Run or Auto Speed position, LED’s
indicate fuel left in tank.

7 Engine Choke Control (Carbureted
Engines Only)

Use control to change engine air-fuel mix
when starting engine.

8 Engine Control Switch
Use switch to start engine, select speed, and

stop engine. In Auto Speed position, engine
runs at appropriate speed according to load
(see Section 6-4). In Run position, engine
runs at 3600 RPM.

Use switch in combination with meters to de­termine total engine hours and hours until
next recommended oil change (see items 2
and 3 earlier in this section).

To Start: pull out choke (if equipped) and
turn Engine Control switch to Start position.
Release switch when engine starts. Slowly
push in choke (if equipped).

 If the engine does not start, let the

engine come to a complete stop before
attempting restart.

 During cold weather some gasoline en-

gines encounter difficulties that are easi­ly remedied. See Section 6-3 and 8-11.

To Stop: turn Engine Control switch to Off
position.

9 Remote Receptacle RC4
Use receptacle to connect remote control or

wire feeder.
When a remote voltage/amperage control is

connected to the Remote receptacle, the
Auto Sense Remote feature automatically
switches voltage/amperage control to the re­mote control (see Sections 5-9 and 6-7).

With remote voltage/amperage control con­nected, weld output in CC mode is deter­mined by a combination of front panel and re­mote control voltage/amperage settings. In
CV mode, weld output is controlled through
remote control only.

If no remote voltage/amperage control is
connected to the Remote receptacle, the
front panel Voltage/Amperage control ad­justs voltage and amperage.

OM-277904 Page 29

 Complete Parts List is available at www.MillerWelds.com

6-3. Cold Weather Engine Operation

Infrequently

1

Loaded

Frequently
Loaded

Ref. 248 009

1 Engine Control Switch

Carburetor Icing

Carburetor icing causes the unit to drop below the normal idle speed and then
stall. This condition occurs when the temperature is near freezing and the rela­tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu­retor. The engine typically restarts without problems but soon stalls again.

 Treat gasoline with a fuel de−icer product (isopropyl alcohol).
 Place the Engine Control switch in the Run position if infrequently loaded.
 Run engine only when expecting to frequently load it.

Breather Icing

Oil breather/pulse line icing occurs in severe cold (continuously below 0F).
Moisture accumulates in the oil from piston ring blow−by if the engine is exten­sively idled. This may cause vacuum line freezing, oil breather tube freezing
or ice in the carburetor. All of these cause operating problems. Due to ice in
the lines, the engine may not restart until it is warmed to above freezing.

 Load engine and reduce idle times to prevent engine shutdowns.
 Use an electric fuel pump to avoid pulse line freezing.
 Install engine cold−weather kit.

Kohler (1-800-544-2444) offers a kit for cold weather operation. The user can
install the kit. The kit pulls heated air from the muffler surface into the carbure­tor and shuts the cold air off. This increases engine temperature during opera­tion in both idle and high speed.

 When the ambient temperatures become warmer (above 45_F) the air

flow will have to be returned to normal.

Synthetic Oil

For temperatures below zero (0º F), synthetic oil improves engine starting. Af­ter the first 50 hours of operation with non−synthetic oil, the engine can be
switched to synthetic oil.

 Do not extend the 100 hour recommended oil change interval.

In severe cold, use synthetic grade 5W30 oil. See engine maintenance label
for additional information.

Notes

OM-277904 Page 30

 Complete Parts List is available at www.MillerWelds.com

6-4. Process/Contactor Switch, Engine Auto Speed, And Arc Control

SOFT

1

18

2

250 916-A / 248 009-A

1 Process/Contactor Switch

! Weld output terminals are energized

when Process/Contactor switch is
in an Output On position and the en­gine is running.

Use switch to select weld process and weld
output on/off control (see Table 6-1 and
Section 5-9).

Place switch in Remote positions to turn
weld output on and off with a device con­nected to the remote receptacle.

Place switch in Output On positions for
weld output to be on whenever the engine
is running.

2 Arc Control
Arc control is active for all Stick and Solid

Wire applications.
For both Stick and Solid Wire applications,

a good starting point is to set this control at
the «.

For Stick applications, the Arc control var-

ies additional amperage during short arc
length conditions.

For Solid Wire applications, the Arc control
varies inductance providing weld fluidity.

In setting shown above, output is available
when the engine is running. Stick process
is chosen using a XX18−type electrode. Arc
Control is set for Soft and the value is
shown on the meters.

Engine Auto Speed

When Engine Control switch is in Auto
Speed position, the engine speed varies
depending on the welding load and Pro­cess/Contactor switch position.

For Gouge, the engine runs at 3600 rpm
and will return to idle about 9 seconds after
the arc is broken.

For Stick, based on preset, unit goes to the
next highest speed upon arc initiation and
transitions down one speed if power is ap­propriate for load.

For TIG, based on preset, unit goes to
speed appropriate for load at arc initiation.

Approximate Amperage/RPM Steps:
0 − 150 A = 2400 RPM

151 − 210 A = 2800 RPM
211 − 260 A = 3200 RPM
261 − 325 A = 3600 RPM

Engine returns to idle about 3 seconds after
the arc is broken if running at less than
2800RPM. If running at more than 3200
RPM, return to idle time is about 9 seconds.

For Solid Wire, unit goes to 3200 rpm upon
arc initiation and transitions down to appro­priate speed for load.

Amperage/RPM Steps and return to idle are
the same as Stick/TIG.

For Flux-Core Wire, unit goes to 3600 rpm
upon arc initiation and transitions down to
appropriate speed for load.

Amperage/RPM Steps and return to idle are
the same as Stick/TIG.

 Miller recommends Hobart filler

metals.

OM-277904 Page 31

 Complete Parts List is available at www.MillerWelds.com

Table 6-1. Process/Contactor Switch And Arc Control Settings

 Arc Control is not active when the Process/Contactor switch is in the following positions:

Output On / Wire / Flux Core
Output On / Stick / Gouge
Remote On/Off / Wire / Flux Core
TIG processes also do not have arc control but process information is included in the table.

 Miller recommends Hobart filler metals.

Process/Contactor Switch Arc Control

SOFT

 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance)

Voltage sensing feeder

SOFT Flat or horizontal welds with XX18 electrode with short weld cables

 (0) Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes

Starting point for stainless steel wire (high inductance)

STIFF Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13

SOFT Starting point for welding pipe with XX10 and XX18 electrodes

 (0) Starting point for XX10 electrode/open root vertical down joint

STIFF Starting point for pipe welding vertical down with long weld cables

Not
Active

electrodes. Also for pipe welding with XX10 and XX18 electrodes

Lift Arc start. No Auto Crater allows full control on pipe welds with
short or long arc length. Auto Stop feature allows arc to be broken
without loss of shielding gas.

OM-277904 Page 32

 Complete Parts List is available at www.MillerWelds.com

Not
Active

Not
Active

Lift Arc start. Optimum for flat joint to end weld with crater fill, allow­ing for addition of filler, without loss of shielding gas

Lift Arc start. Preset maximum current. Unit automatically pulses
maximum output 40% of the time and 25% of peak output for 60%
of the time based on 100 pulses per second. Meters display aver­age output. Auto Stop feature allows arc to be broken without loss
of shielding gas.

Wire feeder connects to
Remote 14 receptacle

Not
Active

SOFT Flat or horizontal welds with XX18 electrode with short weld cables

 (0) Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes

STIFF Starting point for XX10 and XX11 electrodes

SOFT Starting point for stainless steel wire (high inductance)

 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance)

No Lift Arc start; use external high-frequency device or scratch start
TIG

OM-277904 Page 33

 Complete Parts List is available at www.MillerWelds.com

6-5. Stick Start Procedure − Scratch Start Technique

1

2

3

6-6. Lift-Arct TIG With Auto-Cratert And Auto-Stopt

Arc Start With Lift-Arc

12

Arc End With Auto-Crater

12213

OR

Arc End With Auto-Stop

3

4

With Stick selected, start arc as
follows:

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece like

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

 Miller recommends Hobart filler

metals.

Arc Start With Lift-Arc TIG

Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.

Select Lift-Arc at Process/Contac­tor switch.

Turn gas on.
1 Touch or scratch.
2 Lift at any angle.
Touch tungsten electrode to

workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.

Maintain shielding gas coverage
and eliminate tungsten and work­piece contamination by using
Auto-Crater or Auto-Stop to end
the arc.

Arc End With Auto-Crater:

 Remote control is not needed

when using Auto-Crater.

3 While welding.
4 Lift torch slightly to start

Auto-Crater end (current is
reduced).

5 Lower torch. Weld current

ramps down.

6 Shielding gas continues until

shut off.

Arc End With Auto-Stop:

7 While welding.
8 Lift torch to start Auto-Stop.

(Lift higher than that needed
to start Auto-Crater.) Arc
stops.

9 Move torch back down to

maintain gas coverage and
prevent contamination.

 Miller recommends Hobart

filler metals.

OM-277904 Page 34

WM Marketing

 Complete Parts List is available at www.MillerWelds.com

6-7. Remote Voltage/Amperage Control

2

1

1 Remote Receptacle RC4
Connect optional remote voltage/

amperage (V/A) control to RC4
(see Section 5-9).

2 Process/Contactor Switch
With remote control connected,

weld output in Stick or TIG is deter­mined by a combination of front
panel and remote control voltage/
amperage settings. In Wire, weld
output is controlled through remote
control only.

Connect Remote
V/A Control To Re­mote Receptacle
RC4

Set Process

Set V/A Control
(Mid-Range: About 160 A)

Process = Stick (Using Remote On/Off)

In Example:

Min = 30 A CC/DC

Max = 160 A CC/DC

OR

Max (160 A DC)

Min (30 A DC)

Adjust Remote V/A Control
(Stick Welding Only)

803 571−A / 248 009−A / S-0769 / S-0774

OM-277904 Page 35

 Complete Parts List is available at www.MillerWelds.com

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles And Supplementary Protectors

1

3

4

2

5

Ref. 248 009

! Use GFCI protection when operat-

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

! Unplug power cord before attempt-

ing to service accessories or tools.

 Generator power decreases as weld

current increases.

1 120/240 V 50 A AC Receptacle RC1
2 120 V 20 A AC Receptacles RC2

and RC3 (GFCI Receptacles Shown)

! Test GFCI monthly. See Section 7-2

for GFCI information and for reset­ting and testing procedures.

OM-277904 Page 36

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

12.0 kVA/kW.

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

3 Supplementary Protector CB1

CB1 protects standard receptacles RC1,
RC2, and RC3 from overload (for Excel
power information, see Section 7-3). If CB1
opens, the receptacles do not work. Place
switch in On position to reset.

4 Supplementary Protector CB2

CB2 protects RC2 from overload. If CB2
opens, RC2 does not work.

5 Supplementary Protector CB3

CB3 protects RC3 from overload. If CB3
opens, RC3 does not work.

 Press button to reset supplementary

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

Combined output of all receptacles limited
to 12.0 kVA/kW rating of the generator.

EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 30 A is available
at the 120/240V receptacle:

2 x (120 V x 20 A) + (240 V x 30 A) = 12.0
kVA/kW

 Complete Parts List is available at www.MillerWelds.com

GFCI R

d T

7-2.

eceptacle Information, Resetting An

5

esting

1

2

4

3

! Use GFCI protection when operat-

ing auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.

! Unplug power cord before attempt-

ing 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)

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 it replaced by a
Factory Authorized Service Agent.

! Extension cords with bad insulation

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

RotGFCI1 2016-12

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 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 press the GFCI Test but­ton. The GFCI Reset button should pop out.

Press the GFCI Reset button.

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

OM-277904 Page 37

 Complete Parts List is available at www.MillerWelds.com

7-3. Optional Excel Power

60Hz

1

ALL

Speeds

Excel power option provides gener­ator power at idle speed and while
welding. This allows most job site
tools to operate properly at engine
idle speed.

! Use GFCI protection when

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

1 120 V 20 A AC Excel Power

Receptacle

This receptacle supplies 2.4 kVA/
kW of pure 120 V, 60 Hz sine wave
power at ALL engine speeds.

Circuit protection is provided by
CB3 only; CB1 does not provide
protection to Excel power.

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

7-4. Simultaneous Weld And Power

Weld Current in Amperes

At 30 Volts DC

300 2000 10 5
250 3500 20* 15
200 5000 20* 23
150 6500 20* 30
100 8000 20* 35

0 11,000 20* 44

* Limited to receptacle rating.

Total Power in Watts 120 V Receptacle Amperes 240 V Receptacle Amperes

Excel  power

Run Tools at Idle Speed



Ref. 248 009 / 250 717-C

OM-277904 Page 38

 Complete Parts List is available at www.MillerWelds.com

7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.

1 Plug Wired for 120/240 V,

3-Wire Load

When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire

Load

5

3 Neutral (Silver) Terminal
4 Load 1 (Brass)Terminal
5 Load 2 (Brass) Terminal
6 Ground (Green) Terminal
7 Amperes Available using

120/240 V Plug

120V

240V

120V

240V

3

4

4

1

6

2

3

56

Current Available in Amperes

240 V

Receptacle*

0
5
10
15
20
25
30
35
40

*One 240 V load or two 120 V loads.

Each 120 V Duplex

Receptacle

20
20
20
20
20
15
10
5
0

V x A = Watts

240 V AC

120 V AC 120 V AC

7

Tools Needed:

plug1 11/03 − 120 813-D

OM-277904 Page 39

 Complete Parts List is available at www.MillerWelds.com

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Maintenance Label

OM-277904 Page 40

278025A

 Complete Parts List is available at www.MillerWelds.com

8-2. Routine Maintenance

 Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 6-1). The Voltmeter and Ammeter display total engine

operating hours at start-up.

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

! Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

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

Every

8

Hours

Every

25

Hours

Every

50

Hours

Every

100

Hours

Every

200

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Fuel Level  Oil Level  Meters for next oil

change interval

 Spark Arrestor Screen  Air Cleaner Wrapper

 Weld Terminals

 Battery Terminals  Cooling System  Oil  Air Cleaner Element

 Oil, Fuel Spills

Reference

Section 5-4,
6-1, 6-2

Section 8-5,
8-4

Engine
Manual,
Section 8-4
and 8-6

Engine
Manual and
Section 8-6

 Unreadable Labels  Spark Plug Gap  Oil Filter  Fuel Filter

Every

500

Hours

 Weld Cables  Slip Rings*

 Brushes*

NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.

Engine
Manual

8-3. EFI System And Servicing Information

NOTICE − EFI system components can be damaged if this information is not followed:

 Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the Engine Control switch On.
 Never attempt to service any fuel system component while engine is running or the Engine Control switch is On.
 Clean any joint or fitting with approved cleaning solvent before opening to prevent dirt from entering the system.
 Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt can cause significant problems.
 Always depressurize the fuel system through the test valve in the fuel rail before disconnecting or servicing any fuel system components.
 Do not used compressed air if the system is open.
 Avoid direct water or spray contact with system components.

OM-277904 Page 41

 Complete Parts List is available at www.MillerWelds.com

8-4. Servicing Air Cleaner

Kohler−Powered

! Stop engine.

NOTICE − Do not run engine with-
out air cleaner or with dirty element.
Engine damage caused by using a
damaged element is not covered by
the warranty.

1 Precleaner
Wash precleaner with soap and wa-

ter solution. Allow precleaner to air

1

2

dry completely.
Spread 1 tablespoon SAE 30 oil

evenly into precleaner. Squeeze
out excess oil.

2 Element
Replace element if damaged, dirty,

or oily.

oil

8-5. Servicing Optional Spark Arrestor

aircleaner3 5/16 − 802772 / S-0759

! Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

1

Tools Needed:

1/4 in.

OM-277904 Page 42

Ref. 250 916−A / Ref. 183 175−A

 Complete Parts List is available at www.MillerWelds.com

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter

1

! Stop engine and let cool.

1 Oil Drain Valve
Change engine oil and filter accord-

ing to engine owner’s manual.

NOTICE − Close valve and valve
cap before adding oil and running
engine.

Fill crankcase with new oil to full
mark on dipstick (see Section 8-1).

2 Fuel Filter
3 Fuel Line
Replace line if cracked or worn.

Install new filter with arrow pointing
in the direction of fuel flow. Wipe up
any spilled fuel.

Start engine, and check for fuel
leaks.

! Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

Reset oil maintenance countdown
by leaving the engine off and flip­ping Engine Control switch from
Auto Speed to Run three times.

Oil Fill

2

3

Oil Check

Tools Needed:

Full

250 916-A

OM-277904 Page 43

8-7. Overload Protection

 Complete Parts List is available at www.MillerWelds.com

3

! Stop engine.

Open left side door.

 When a supplementary protec-

tor or fuse opens, it usually indi­cates a more serious problem
exists. Contact a Factory Au­thorized Service Agent.

 Supplementary Protector CB4

and Circuit Breaker CB5 are
located on the engine baffle be­hind the left side panel.

1 Supplementary Protector CB4

(Not Shown)

CB4 protects the stator winding
supplying 24 volt AC output to Re­mote receptacle RC4. If CB4
opens, 24 volt AC output to RC4
stops.

Press button to reset.
2 Circuit Breaker CB5 (Not

Shown)

CB5 protects the optional Excel
power windings from overload. If
CB5 opens, Excel power is not
available at receptacle RC3.

Place switch in On position to reset.
3 Fuse F6 (See Parts List)
F6 protects the engine wiring sys-

tem from overload. If F6 opens,
engine will not crank.

4 Fuse F5
F5 protects the weld excitation

winding from overload and excess­ive open-circuit voltage. If F5
opens, weld and auxiliary power
output stops. If F5 opens right after
replacement, contact Factory Au­thorized Service Agent.

Replace fuse if open.
Close left side door.

 Fuse F5 is located on

engine baffle behind
right side panel.

4

161 001 / 250 916-A

8-8. Engine Speed Adjustment

Engine speed is controlled by an electronic governor. Engine speed adjustments must be made by and engine Factory Authorized Service Agent.
Tampering with adjustments may affect engine warranty.

OM-277904 Page 44

 Complete Parts List is available at www.MillerWelds.com

8-9. Welding Troubleshooting

Trouble Remedy

No weld output. Check weld control settings.

Check weld connections.

Disconnect equipment from generator power receptacles during start-up.

Increase front panel and/or remote voltage/amperage control settings (see Sections 5-9 and 6-1).

Check and secure connections to Remote receptacle RC4 (see Sections 5-9).

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

Low weld output. Check weld control settings.

Increase front panel and/or remote voltage/amperage control settings (see Sections 5-9 and 6-1).

Check and clean air cleaner as necessary (see Section 8-4).

Have engine Factory Authorized Service Agent check engine speed.

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

See engine manual.

No weld output and no auxiliary power. Have Factory Authorized Service Agent check fuse F5.

High weld output. Check weld control settings.

Have engine Factory Authorized Service Agent check engine speed.

Have Factory Authorized Service Agent check circuit boards PC1 and PC2.

Weld output cannot be adjusted. Have Factory Authorized Service Agent check control board PC2.

Erratic weld output.

No remote voltage/amperage control. Check and tighten connections to Remote receptacle RC4 (see Section 5-9). Check and secure lead

No front panel voltage/amperage
control.

Check weld control settings.

Clean and tighten connections both inside and outside unit.

Check and secure lead connections to remote control.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Use dry, properly stored electrodes.

Have engine Factory Authorized Service Agent check engine speed.

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

Check shielding gas, ensure proper shielding gas coverage while welding.

connections to remote control.

Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
5-9).

No 24 volt AC power output at Remote
receptacle RC4.

Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld­ing arc.

Reset supplementary protector CB4 (see Section 8-7).

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.

OM-277904 Page 45

Trouble Remedy

Wandering arc − poor control of arc
direction.

 Complete Parts List is available at www.MillerWelds.com

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

8-10. Generator Power Troubleshooting

Trouble Remedy

No power output. Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 7-1).

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

No Excel power output. Reset supplementary protector CB3 (see Section 7-1). If Excel power is still not available, check

Low power output. Check and clean air cleaner as necessary.

No weld output and no auxiliary power. Have Factory Authorized Service Agent check fuse F5.

High power output. Have engine Factory Authorized Service Agent check engine speed.

Erratic power output. Have Factory Authorized Service Agent check brushes, slip rings, and control board PC2.

circuit breaker CB5 (see Section 8-7).

Have engine Factory Authorized Service Agent check engine speed.

See engine manual.

Check receptacle wiring and connections.

Have engine Factory Authorized Service Agent check engine speed.

8-11. Engine Troubleshooting

Trouble Remedy

Engine will not crank. Check fuse F6, and replace if open (see Section 8-7).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

Engine does not start. Check fuel level (see Section 5-4).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual (car­bureted engines only).

See engine manual.

OM-277904 Page 46

 Complete Parts List is available at www.MillerWelds.com

Trouble Remedy

Engine starts but stops when Engine
Control switch returns to Auto Speed
position.

Battery discharges between uses. Place Engine Control switch in Off position when unit is not running.

Engine stopped during normal
operation.

Engine does not return to idle speed. Be sure Engine Control switch S2 is in Auto Speed position.

During operation in near freezing tem­peratures, engine starts and goes to
idle but stalls after a few minutes.

Check oil level (see Section 5-4). Low oil pressure shutdown stops engine if oil pressure is too low.

Use correct grade oil for operating temperature. (see Section 8-1).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Clean top of battery with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

Check fuel level (see Section 5-4).

Check oil level (see Section 5-4). Low oil pressure shutdown stops engine if oil pressure is too low.
Oil level too high reduces capacity of the fuel pump (carbureted engines only).

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual (car­bureted engines only).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Remove all weld and generator power loads.

Turn off remote device connected to Remote receptacle RC4 (see Section 5-9).

Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.

Treat fuel with isopropyl alcohol de-icer product.

Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri­od of time.

During operation in severe cold weath­er, engine starts and goes to idle but
stalls after a few minutes.

Install engine manufacturer’s kit for cold-weather operation (carbureted engines only).

OM-277904 Page 47

 Complete Parts List is available at www.MillerWelds.com

SECTION 9 − PARTS LIST

 A complete Parts List is available on-line at www.MillerWelds.com.

9-1. Recommended Spare Parts

Dia.

Mkgs.

F6 215621 Fuse, 30 Amp Ato Type 1........... ..... .. ..........................................

NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.

Part

No.

Recommended Spare Parts

230015 Tune−up & Filter Kit, Kohler CH730 (Includes) 1.................... .. ......................

230016 Air Filter Element 1.................... .... .............................................

066698 Oil Filter 1.................... .... .....................................................

215985 Filter, Fuel w/Clamps & 1/4 in Fuel Line 1.................... .... ..........................

067007 Spark Plug 2.................... .... ...................................................

230017 Air Filter Wrapper 1.................... .... .............................................

246115 Tune−up & Filter Kit, Kohler ECH730 (includes) 1.................... .. .....................

230016 Air Filter Element 1.................... .... .............................................

066698 Oil Filter 1.................... .... .....................................................

246117 Filter, Fuel w/Clamps (Primary) 1.................... .... ..................................

246123 Filter, Fuel w/Clamps (Secondary) 1.................... .... ...............................

067007 Spark Plug 2.................... .... ...................................................

230017 Air Filter Wrapper 1.................... .... .............................................

Description

Quantity

OM-277904 Page 48

Notes

 Complete Parts List is available at www.MillerWelds.com

OM-277904 Page 49

SECTION 10 − ELECTRICAL DIAGRAMS

OM-277904 Page 50

Figure 10−1. Circuit Diagram For Welder/Generator

OM-277904 Page 51

276902-A

SECTION 11 − GENERATOR POWER GUIDELINES

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

11-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

gen_pwr 2014−09 − ST-800 577

OR

1

2

3

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

3

! Always ground generator frame to

vehicle frame to prevent electric
shock and static electricity hazards.

! Also see AWS Safety & Health Fact

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

1 Equipment Grounding Terminal (On

Front Panel)

2 Grounding Cable (Not Supplied)

3 Metal Vehicle Frame
Connect cable from equipment ground

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

 Electrically bond generator frame to ve-

hicle frame by metal-to-metal contact.

! Bed liners, shipping skids, and

some running gear insulate the
welder/generator from the vehicle

2

800 652-D

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

! Use GFCI protection when operat-

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

OM-277904 Page 52

11-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #8 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

11-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115

4.5

AMPS

60

Hz

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-

sistive load and requires approxi­mately six times more power while
starting the motor than when running
(see Section 11-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

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

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

watts.
Example 2: If three 200 watt flood

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

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

flood lamps and drill is 1120 watts.

S-0623

OM-277904 Page 53

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

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

10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-277904 Page 54

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in. 350 350

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

Circular Saw 6-1/2 in. 500 500

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

Table Saw 9 in. 4500 1500

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

8 in. 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

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

2 HP, 14 in. 1100 1100

Electric Trimmer Standard 9 in. 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in. 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-277904 Page 55

11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage
3 Motor HP
4 Motor Voltage
To find starting amperage:

Step 1: Find code and use table to

4
1
3

VOLTS AMPS

CODE 60

HP

AC MOTOR
230 2.5
M
1/4

Hz
PHASE

1

2

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

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

age (see example).
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.

11-9. How Much Power Can Generator Supply?

1

2

S-0624

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

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

OM-277904 Page 56

11-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

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

! Properly install, ground, and

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

 Customer-supplied equipment

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

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

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

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

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welder/Generator Output
Generator output voltage and wir-

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

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

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

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-277904 Page 57

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

Cord Lengths for 120 Volt Loads

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

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

Load (Watts) 4 6 8 10 12 14

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 (AWG)*

Current

(Amperes)

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop
OM-277904 Page 58

Load (Watts) 4 6 8 10 12 14

Warranty Questions?

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

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

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

Effective January 1, 2017

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

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective date of
this limited warranty is free of defects in material and workmanship at
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS.

Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
or workmanship. Miller must be notified in writing within thirty (30) days
of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted
as an online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.

Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.

1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)

* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)

* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns, Subarc (SAW) Torches, and External

Cladding Heads
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Spoolmate Spoolguns

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

miller_warr 2017-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.