OM-282374C 2018−11

Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welder/Generator And

Air Compressor

) )
Big Blue 800 X Duo Air Pak
Deutz

For product information, File: Engine Drive

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

Miller Electric manufactures a full line

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

Mil_Thank 2017−06
 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 Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-5. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-8. AC Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5. Using The Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 28
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 29
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 30
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . 31
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 32
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 33
5-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-15. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-16. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

WARNING: Breathing diesel engine exhaust exposes you to chemicals

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

5-17. Connecting To Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5-18. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6-3. Engine Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6-4. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6-5. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6-6. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6-7. Dynamic Dig Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6-8. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6-9. Lift-Arc TIG With Auto-Stop And Auto-Crater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6-10. Voltage/Amperage Control With 14-Pin Remote Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6-11. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6-12. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6-13. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6-14. Associating ArcReach Devices (ArcReach Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6-15. Operating Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6-16. Optional Air Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7-1. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8-3. Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8-5. Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8-6. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8-7. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8-8. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8-10. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8-11. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8-12. Removing Optional Air Dryer For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SECTION 9 − AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9-1. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9-2. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-3. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-4. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9-5. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-6. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SECTION 13 − ENGINE INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SECTION 14 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
14-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
14-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SECTION 15 − AIR COMPRESSOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. . . 91
SECTION 16 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2018−06

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards

 Disconnect input power or stop engine before installing or
The symbols shown below are used throughout this manual servicing this equipment. Lockout/tagout input power according to
to call attention to and identify possible hazards. When you
OSHA 29 CFR 1910.147 (see Safety Standards).
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is  Properly install, ground, and operate this equipment according to
only a summary of the more complete safety information its Owner’s Manual and national, state, and local codes.
found in the Safety Standards listed in Section 1-7. Read and  Always verify the supply ground — check and be sure that input
follow all Safety Standards. power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
Only qualified persons should install, operate, maintain, and grounded receptacle outlet.
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or  When making input connections, attach proper grounding conduc-
professional standing, or who by extensive knowledge, train- tor first − double-check connections.
ing and experience, has successfully demonstrated ability to  Keep cords dry, free of oil and grease, and protected from hot metal
solve or resolve problems relating to the subject matter, the and sparks.
work, or the project and has received safety training to recog-  Frequently inspect input power cord and ground conductor for
nize and avoid the hazards involved. damage or bare wiring – replace immediately if damaged – bare
During operation, keep everybody, especially children, away. wiring can kill.
 Turn off all equipment when not in use.
ELECTRIC SHOCK can kill.  Do not use worn, damaged, undersized, or repaired cables.
 Do not drape cables over your body.
Touching live electrical parts can cause fatal shocks  If earth grounding of the workpiece is required, ground it directly
or severe burns. The electrode and work circuit is with a separate cable.
electrically live whenever the output is on. The input  Do not touch electrode if you are in contact with the work, ground,
power circuit and machine internal circuits are also or another electrode from a different machine.
live when power is on. In semiautomatic or automat-
ic wire welding, the wire, wire reel, drive roll housing,  Use only well-maintained equipment. Repair or replace damaged
and all metal parts touching the welding wire are parts at once. Maintain unit according to manual.
electrically live. Incorrectly installed or improperly  Do not touch electrode holders connected to two welding ma-
grounded equipment is a hazard. chines at the same time since double open-circuit voltage will be
present.
 Do not touch live electrical parts.  Wear a safety harness if working above floor level.
 Wear dry, hole-free insulating gloves and body protection.  Keep all panels and covers securely in place.
 Insulate yourself from work and ground using dry insulating mats  Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground.  Insulate work clamp when not connected to workpiece to prevent
 Do not use AC weld output in damp, wet, or confined spaces, or if contact with any metal object.
there is a danger of falling.  Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
 Use AC output ONLY if required for the welding process. use.
 If AC output is required, use remote output control if present on unit.  Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
 Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp SIGNIFICANT DC VOLTAGE exists in inverter power
locations or while wearing wet clothing; on metal structures such sources AFTER stopping engine.
as floors, gratings, or scaffolds; when in cramped positions such  Stop engine on inverter and discharge input capacitors according
as sitting, kneeling, or lying; or when there is a high risk of unavoid- to instructions in Manual before touching any parts.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
HOT PARTS can burn.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
 Do not touch hot parts bare handed.
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!  Allow cooling period before working on
equipment.
 Do not connect to any electrical distribution system normally sup-
plied by utility power unless a proper transfer switch and grounding  To handle hot parts, use proper tools and/or wear heavy, insu-
procedure are employed. lated welding gloves and clothing to prevent burns.

OM-282374 Page 1
  Watch for fire, and keep a fire extinguisher nearby.
FLYING METAL or DIRT can injure
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
eyes. cause fire on the hidden side.
 Welding, chipping, wire brushing, and grinding  Do not cut or weld on tire rims or wheels. Tires can explode if heat-
cause sparks and flying metal. As welds cool, ed. Repaired rims and wheels can fail. See OSHA 29 CFR
they can throw off slag. 1910.177 listed in Safety Standards.
 Wear approved safety glasses with side shields even under your  Do not weld on containers that have held combustibles, or on
welding helmet. closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
FUMES AND GASES can be Safety Standards).
hazardous.  Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
Welding produces fumes and gases. Breathing these
 Connect work cable to the work as close to the welding area as practi-
fumes and gases can be hazardous to your health.
cal to prevent welding current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
 Keep your head out of the fumes. Do not breathe the fumes.  Do not use welder to thaw frozen pipes.
 Ventilate the work area and/or use local forced ventilation at the arc  Remove stick electrode from holder or cut off welding wire at
to remove welding fumes and gases. The recommended way to contact tip when not in use.
determine adequate ventilation is to sample for the composition  Wear body protection made from durable, flame-resistant material
and quantity of fumes and gases to which personnel are exposed. (leather, heavy cotton, wool). Body protection includes oil-free
 If ventilation is poor, wear an approved air-supplied respirator. clothing such as leather gloves, heavy shirt, cuffless trousers, high
 Read and understand the Safety Data Sheets (SDSs) and the shoes, and a cap.
manufacturer’s instructions for adhesives, coatings, cleaners,  Remove any combustibles, such as a butane lighter or matches,
consumables, coolants, degreasers, fluxes, and metals. from your person before doing any welding.
 Work in a confined space only if it is well ventilated, or while  After completion of work, inspect area to ensure it is free of sparks,
wearing an air-supplied respirator. Always have a trained watch- glowing embers, and flames.
person nearby. Welding fumes and gases can displace air and
 Use only correct fuses or circuit breakers. Do not oversize or by-
lower the oxygen level causing injury or death. Be sure the breath-
pass them.
ing air is safe.
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
 Do not weld in locations near degreasing, cleaning, or spraying op-
for hot work and have a fire watcher and extinguisher nearby.
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.  Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
 Do not weld on coated metals, such as galvanized, lead, or
consumables, coolants, degreasers, fluxes, and metals.
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied NOISE can damage hearing.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded. Noise from some processes or equipment can
BUILDUP OF GAS can injure or kill. damage hearing.
 Wear approved ear protection if noise level is
 Shut off compressed gas supply when not in use. high.
 Always ventilate confined spaces or use ap-
proved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
ARC RAYS can burn eyes and skin.  Wearers of Pacemakers and other Implanted
Arc rays from the welding process produce intense Medical Devices should keep away.
visible and invisible (ultraviolet and infrared) rays  Implanted Medical Device wearers should con-
that can burn eyes and skin. Sparks fly off from the sult their doctor and the device manufacturer before going near arc
weld. welding, spot welding, gouging, plasma arc cutting, or induction heat-
 Wear an approved welding helmet fitted with a proper shade of filter ing operations.
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in CYLINDERS can explode if damaged.
Safety Standards). Compressed gas cylinders contain gas under high
 Wear approved safety glasses with side shields under your pressure. If damaged, a cylinder can explode. Since
helmet. gas cylinders are normally part of the welding
 Use protective screens or barriers to protect others from flash, process, be sure to treat them carefully.
glare, and sparks; warn others not to watch the arc.
 Protect compressed gas cylinders from excessive heat, mechani-
 Wear body protection made from durable, flame-resistant material
cal shocks, physical damage, slag, open flames, sparks, and arcs.
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high  Install cylinders in an upright position by securing to a stationary
shoes, and a cap. support or cylinder rack to prevent falling or tipping.
 Keep cylinders away from any welding or other electrical circuits.
WELDING can cause fire or explosion.  Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
Welding on closed containers, such as tanks,  Never weld on a pressurized cylinder — explosion will result.
drums, or pipes, can cause them to blow up. Sparks  Use only correct compressed gas cylinders, regulators, hoses,
can fly off from the welding arc. The flying sparks, hot and fittings designed for the specific application; maintain them
workpiece, and hot equipment can cause fires and and associated parts in good condition.
burns. Accidental contact of electrode to metal objects can cause  Turn face away from valve outlet when opening cylinder valve. Do
sparks, explosion, overheating, or fire. Check and be sure the area is not stand in front of or behind the regulator when opening the valve.
safe before doing any welding.  Keep protective cap in place over valve except when cylinder is in
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If use or connected for use.
this is not possible, tightly cover them with approved covers.  Use the proper equipment, correct procedures, and sufficient
 Do not weld where flying sparks can strike flammable material. number of persons to lift, move, and transport cylinders.
 Protect yourself and others from flying sparks and hot metal.  Read and follow instructions on compressed gas cylinders,
 Be alert that welding sparks and hot materials from welding can associated equipment, and Compressed Gas Association (CGA)
easily go through small cracks and openings to adjacent areas. publication P-1 listed in Safety Standards.
OM-282374 Page 2
1-3. Engine Hazards

BATTERY EXPLOSION can injure. EXHAUST SPARKS can cause fire.

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

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can  Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill. structions.
 Incorrect installation or operation of this unit  Do not modify or alter compressor or manufacturer-supplied
could result in equipment failure and personal equipment. Do not disconnect, disable, or override any safety
injury. Only qualified persons should install, op- equipment in the compressed air system.
erate, and service this unit according to its  Use only components and accessories approved by the manufac-
Owner’s Manual, industry standards, and na- turer.
tional, state, and local codes.  Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not exceed the rated output or capacity of the compressor or  Do not work under or around any equipment that is supported only
any equipment in the compressed air system. Design compressed by air pressure. Properly support equipment by mechanical
air system so failure of any component will not put people or prop- means.
erty at risk.
 Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
OM-282374 Page 3
 HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
 Keep away from moving parts such as fans,
 Do not cut or gouge near flammables. belts and rotors.
 Watch for fire; keep extinguisher nearby.  Keep all doors, panels, covers, and guards
closed and securely in place.
 Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
 Before working on compressed air system,  Before working on compressed air system, turn off and lockout/
turn off and lockout/tagout unit, release pres- tagout unit, release pressure, and be sure air pressure cannot be
sure, and be sure air pressure cannot be acci- accidentally applied.
dentally applied.  Have only qualified people remove guards or covers for maint-
 Relieve pressure before disconnecting or con- enance and troubleshooting as necessary.
necting air lines.  Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
 Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
 Do not direct air stream toward self or others.
HOT PARTS can burn.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and  Do not touch hot compressor or air system
a cap when working on compressed air system. parts.
 Use soapy water or an ultrasonic detector to search for  Allow cooling period before working on
leaks−−never use bare hands. Do not use equipment if leaks are equipment.
found.
 To handle hot parts, use proper tools and/or wear heavy, insu-
 Reinstall doors, panels, covers, or guards when servicing is lated welding gloves and clothing to prevent burns.
finished and before starting unit.
 If ANY air is injected into the skin or body seek medical help im-
mediately.

BREATHING COMPRESSED AIR can in-

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

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

FIRE OR EXPLOSION hazard. OVERHEATING can damage motors.

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

OM-282374 Page 4
 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards.
EXPLOSION can injure.
 Put on grounded wrist strap BEFORE handling
Battery charging not present on all models. boards or parts.
 Always wear a face shield, rubber gloves, and  Use proper static-proof bags and boxes to
protective clothing when working on a battery. store, move, or ship PC boards.
 Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery.
 Do not allow tools to cause sparks when working on a battery. TILTING OF TRAILER can injure.
 Do not use welder to charge batteries or jump start vehicles un-
less it has a battery charging feature designed for this purpose.  Use tongue jack or blocks to support weight.
 Observe correct polarity (+ and −) on batteries.  Properly install welding generator onto trailer
according to instructions supplied with trailer.
 Disconnect negative (−) cable first and connect it last.
 Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
READ INSTRUCTIONS.
 Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety  Read and follow all labels and the Owner’s
Standards) for additional information. Manual carefully before installing, operating, or
 Have only qualified persons do battery charging work. servicing unit. Read the safety information at
 If battery is being removed from a vehicle for charging, discon- the beginning of the manual and in each
nect negative (−) cable first and connect it last. To prevent an arc, section.
make sure all accessories are off.  Use only genuine replacement parts from the manufacturer.
 Charge lead-acid batteries only. Do not use battery charger to  Perform installation, maintenance, and service according to the
supply power to an extra-low-voltage electrical system or to Owner’s Manuals, industry standards, and national, state, and
charge dry cell batteries. local codes.
 Do not charge a frozen battery.
 Do not use damaged charging cables.
H.F. RADIATION can cause interference.
 Do not charge batteries in a closed area or where ventilation is
restricted.
 High-frequency (H.F.) can interfere with radio
 Do not charge a battery that has loose terminals or one showing navigation, safety services, computers, and
damage such as a cracked case or cover. communications equipment.
 Before charging battery, select correct charger voltage to match
battery voltage.  Have only qualified persons familiar with electronic equipment
perform this installation.
 Set battery charging controls to the Off position before connect-
ing to battery. Do not allow battery charging clips to touch each  The user is responsible for having a qualified electrician
other. promptly correct any interference problem resulting from the
installation.
 Keep charging cables away from vehicle hood, door, or moving
parts.  If notified by the FCC about interference, stop using the
equipment at once.
HIGH PRESSURE FLUIDS can injure or kill.  Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep
 Engine fuel system components can be under spark gaps at correct setting, and use grounding and shielding to
high pressure. minimize the possibility of interference.
 Before working on fuel system, turn off engine
to release pressure.
 If any fluid is injected into the skin or body seek medical help im- ARC WELDING can cause interference.
mediately.
 Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
WELDING WIRE can injure. processors, computers, and computer-driven
equipment such as robots.
 Do not press gun trigger until instructed to do
so.  Be sure all equipment in the welding area is electromagnetically
compatible.
 Do not point gun toward any part of the body,
other people, or any metal when threading  To reduce possible interference, keep weld cables as short as
welding wire. possible, close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
OVERUSE can cause OVERHEATING.
 Be sure this welding machine is installed and grounded
 Allow cooling period; follow rated duty cycle. according to this manual.
 Reduce current or reduce duty cycle before  If interference still occurs, the user must take extra measures
starting to weld again. such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
 Do not block or filter airflow to unit.

OM-282374 Page 5
1-6. California Proposition 65 Warnings
For Diesel Engines:

WARNING: This product can expose you to chemicals in- WARNING: Breathing diesel engine exhaust exposes you to
cluding lead, which are known to the state of California to chemicals known to the state of California to cause cancer
cause cancer and birth defects or other reproductive and birth defects or other reproductive harm.
harm.  Always start and operate the engine in a well−ventilated
area.
For more information, go to www.P65Warnings.ca.gov.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safe Practice For Occupational And Educational Eye And Face Protec-
is available as a free download from the American Welding Society at tion, ANSI Standard Z87.1, from American National Standards Institute,
http://www.aws.org or purchased from Global Engineering Documents 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
(phone: 1-877-413-5184, website: www.global.ihs.com). site: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding Standard for Fire Prevention During Welding, Cutting, and Other Hot
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Work, NFPA Standard 51B, from National Fire Protection Association,
al Engineering Documents (phone: 1-877-413-5184, website: Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
www.global.ihs.com). OSHA, Occupational Safety and Health Standards for General Indus-
Safe Practices for Welding and Cutting Containers that have Held Com- try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
bustibles, American Welding Society Standard AWS A6.0, from Global N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern-
Engineering Documents (phone: 1-877-413-5184, ment Printing Office, Superintendent of Documents, P.O. Box 371954,
website: www.global.ihs.com). Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OS-
National Electrical Code, NFPA Standard 70, from National Fire Protec- HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
tion Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: website: www.osha.gov).
www.nfpa.org and www. sparky.org). Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
from Compressed Gas Association, 14501 George Carter Way, (phone: 301-504-7923, website: www.cpsc.gov).
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
website:www.cganet.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS For Standards regulating hydraulic systems, contact the National Fluid
(phone: 800-463-6727, website: www.csagroup.org). Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian WI 53214 (phone: (414) 778-3344, website: www.nfpa.com).
Standards Association, Standards Sales, 5060 Spectrum Way, Suite Battery Service Manual, Battery Council International, 330 North
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.csagroup.org). website: www.batterycouncil.org).

1-8. EMF Information

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

OM-282374 Page 6
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2018−06_fre

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

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on  Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

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

assises, à genoux et allongées; ou quand il y a un risque important
Les symboles présentés ci-après sont utilisés tout au long du de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
présent manuel pour attirer votre attention et identifier les ris- les appareils suivants dans l’ordre de préférence: 1) un poste à
ques de danger. Lorsque vous voyez un symbole, soyez souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
vigilant et suivez les directives mentionnées afin d’éviter tout à souder manuel (électrode enrobée) DC, 3) un poste à souder
danger. Les consignes de sécurité présentées ci-après ne manuel AC avec tension à vide réduite. Dans la plupart des cas, un
font que résumer l’information contenue dans les normes de poste courant continu de type CV est recommandé. Et, ne pas tra-
sécurité énumérées à la section 2-7. Veuillez lire et respecter vailler seul!
toutes ces normes de sécurité.
 Ne brancher aucun système de distribution électrique norma-
L’installation, l’utilisation, l’entretien et les réparations ne lement fourni par un réseau public à moins qu’un commutateur de
doivent être confiés qu’à des personnes qualifiées. Une transfert et une procédure de mise à la terre adéquats ne soient
personne qualifiée est définie comme celle qui, par la mis en place.
possession d’un diplôme reconnu, d’un certificat ou d’un  Couper l’alimentation ou arrêter le moteur avant de procéder à
statut professionnel, ou qui, par une connaissance, une for- l’installation, à la réparation ou à l’entretien de l’appareil.
mation et une expérience approfondies, a démontré avec Déverrouiller l’alimentation selon la norme OSHA 29 CFR
succès sa capacité à résoudre les problèmes liés à la tâche, 1910.147 (voir normes de sécurité).
le travail ou le projet et a reçu une formation en sécurité afin  Installer et mettre à la terre correctement cet appareil conformé-
de reconnaître et d’éviter les risques inhérents. ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Au cours de l’utilisation, tenir toute personne à l’écart et plus  Toujours vérifier la terre du cordon d’alimentation − Vérifier et
particulièrement les enfants. s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
UN CHOC ÉLECTRIQUE peut tuer. cordon est raccordée à une prise correctement mise à la terre.
 En effectuant les raccordements d’entrée fixer d’abord le conduc-
Un simple contact avec des pièces électriques peut teur de mise à la terre approprié et contre-vérifier les connexions.
provoquer une électrocution ou des blessures  Les câbles doivent être exempts d’humidité, d’huile et de graisse;
graves. L’électrode et le circuit de soudage sont protégez−les contre les étincelles et les pièces métalliques
sous tension dès que l’appareil est sur ON. Le circuit chaudes.
d’entrée et les circuits internes de l’appareil sont
 Vérifier fréquemment le cordon d’alimentation et le conducteur de
également sous tension à ce moment-là. En souda-
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
ge semi-automatique ou automatique, le fil, le
le remplacer immédiatement s’il l’est −. Un fil dénudé peut en-
dévidoir, le logement des galets d’entraînement et traîner la mort.
les pièces métalliques en contact avec le fil de
 Mettre l’appareil hors tension quand on ne l’utilise pas.
soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.  Ne pas utiliser des câbles usés, endommagés, sous dimension-
nés ou réparés.
 Ne jamais toucher les pièces électriques sous tension.  Ne pas enrouler les câbles autour du corps.
 Porter des gants et des vêtements de protection secs ne compor-  Si la pièce soudée doit être mise à la terre, le faire directement
tant pas de trous. avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres câble de retour.
moyens isolants suffisamment grands pour empêcher le contact  Ne pas toucher l’électrode quand on est en contact avec la pièce,
physique éventuel avec la pièce ou la terre. la terre ou une électrode provenant d’une autre machine.
 Ne pas utiliser de sortie de soudage CA dans des zones humides  Ne pas toucher des porte électrodes connectés à deux machines
ou confinées ou s’il y a un risque de chute. en même temps à cause de la présence d’une tension à vide dou-
blée.
 Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
 Si l’utilisation d’une source électrique à courant électrique s’avère conformément à ce manuel.
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.  Ne pas toucher aux portes−électrodes qui sont raccordés à deux
machines à souder en même temps, car cela entraîne la présence
 Des précautions de sécurité supplémentaires sont requises dans
d’une tension de circuit−ouvert double.
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé-  Porter un harnais de sécurité quand on travaille en hauteur.
talliques au sol, grillages et échafaudages; dans des positions  Maintenir solidement en place tous les panneaux et capots.
OM-282374 Page 7
 Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près pos- LES ACCUMULATIONS DE GAZ
sible de la soudure. risquent de provoquer des blessures
 Isoler la pince de masse quand pas mis à la pièce pour éviter le ou même la mort.
contact avec tout objet métallique.
 Fermer l’alimentation du gaz comprimé en cas
 Ne pas raccorder plus d’une électrode ou plus d’un câble de de non utilisation.
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.  Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
 Utiliser une protection GFCI lors de l’utilisation d’appareils auxi-
liaires. Testez les prises GFCI à haute vitesse. LES RAYONS DE L’ARC peuvent
Il reste une TENSION DC NON NÉGLIGEABLE dans les provoquer des brûlures dans les
sources de soudage onduleur UNE FOIS le moteur coupé. yeux et sur la peau.
 Arrêtez le moteur sur l’onduleur et déchargez les condensateurs Le rayonnement de l’arc du procédé de soudage
d’entrée conformément aux instructions du manuel avant de tou- génère des rayons visibles et invisibles intenses
cher les pièces. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
LES PIÈCES CHAUDES peuvent soudage.
provoquer des brûlures.
 Porter un casque de soudage approuvé muni de verres filtrants
 Ne pas toucher à mains nues les parties chau- approprié pour protéger visage et yeux pour protéger votre visage
des. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
 Prévoir une période de refroidissement avant et Z87.1 énuméré dans les normes de sécurité).
de travailler à l’équipement.  Porter des lunettes de sécurité avec écrans latéraux même sous
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- votre casque.
dés et porter des gants de soudage et des vêtements épais pour  Avoir recours à des écrans protecteurs ou à des rideaux pour
éviter les brûlures. protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
DES PIECES DE METAL ou DES  Porter un équipement de protection pour le corps fait d’un matériau
SALETES peuvent provoquer résistant et ignifuge (cuir, coton robuste, laine). La protection du
des blessures dans les yeux. corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un

 Le soudage, l’écaillement, le passage de la pièce à la brosse en fil
de fer, et le meulage génèrent des étincelles et des particules mé- incendie ou une explosion.
talliques volantes. Pendant la période de refroidissement des Le soudage effectué sur des conteneurs fermés tels
soudures, elles risquent de projeter du laitier. que des réservoirs, tambours ou des conduites peut
 Porter des lunettes de sécurité avec écrans latéraux ou un écran provoquer leur éclatement. Des étincelles peuvent
facial. être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
LES FUMÉES ET LES GAZ peu- incendies et des brûlures. Le contact accidentel de l’électrode avec
vent être dangereux. des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
Le soudage génère des fumées et des gaz. Leur vérifier et s’assurer que l’endroit ne présente pas de danger.
inhalation peut être dangereux pour votre santé.
 Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
 Eloigner votre tête des fumées. Ne pas respirer les fumées. soigneusement avec des protections homologués.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au  Ne pas souder dans un endroit là où des étincelles peuvent tomber
niveau de l’arc pour l’évacuation des fumées et des gaz de sur des substances inflammables.
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de  Se protéger et d’autres personnes de la projection d’étincelles et
fumées et de gaz auxquelles est exposé le personnel. de métal chaud.
 Des étincelles et des matériaux chauds du soudage peuvent
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs
facilement passer dans d’autres zones en traversant de petites
approuvé.
fissures et des ouvertures.
 Lire et comprendre les fiches de données de sécurité et les instruc-  Surveiller tout déclenchement d’incendie et tenir un extincteur à
tions du fabricant concernant les adhésifs, les revêtements, les proximité.
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.  Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à  Ne pas effectuer le soudage sur des conteneurs fermés tels que
un surveillant dûment formé de se tenir à proximité. Des fumées et des réservoirs, tambours, ou conduites, à moins qu ils n aient
des gaz de soudage peuvent déplacer l’air et abaisser le niveau été préparés correctement conformément à AWS F4.1 et AWS
d’oxygène provoquant des blessures ou des accidents mortels. A6.0 (voir les Normes de Sécurité).
S’assurer que l’air de respiration ne présente aucun danger.  Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
 Ne pas souder dans des endroits situés à proximité d’opérations exemple).
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-  Brancher le câble de masse sur la pièce le plus près possible de la
mer des gaz hautement toxiques et irritants. zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier quant des risques d’électrocution, d’étincelles et d’incendie.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit  Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
bien ventilé, et en portant un respirateur à alimentation d’air. Les lées.
revêtements et tous les métaux renfermant ces éléments peuvent  En cas de non utilisation, enlever la baguette d’électrode du porte-
dégager des fumées toxiques en cas de soudage. électrode ou couper le fil à la pointe de contact.
OM-282374 Page 8
 Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
Si des BOUTEILLES sont endomma-
corps comporte des vêtements sans huile comme par ex. des gées, elles pourront exploser.
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette. Des bouteilles de gaz comprimé protecteur contien-
 Avant de souder, retirer toute substance combustible de vos po- nent du gaz sous haute pression. Si une bouteille est
ches telles qu’un allumeur au butane ou des allumettes. endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du procédé de soudage, les
 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra- manipuler avec précaution.
ce d’étincelles incandescentes ni de flammes.
 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.  Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
Ne pas augmenter leur puissance; ne pas les ponter. des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un  Placer les bouteilles debout en les fixant dans un support station-
extincteur à proximité. naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
 Lire et comprendre les fiches de données de sécurité et les instruc-
tions du fabricant concernant les adhésifs, les revêtements, les  Tenir les bouteilles éloignées des circuits de soudage ou autres
nettoyants, les consommables, les produits de refroidissement, circuits électriques.
les dégraisseurs, les flux et les métaux.
 Ne jamais placer une torche de soudage sur une bouteille à gaz.
LE BRUIT peut affecter l’ouïe.  Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Le bruit des processus et des équipements peut
affecter l’ouïe.  Ne jamais souder une bouteille pressurisée − risque d’explosion.

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

2-3. Dangers existant en relation avec le moteur

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

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

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

 Les sources d’étincelles, flammes nues, cigarettes et autres  Maintenir fermés et verrouillés les portes, panneaux,
sources d’inflammation doivent être maintenues à l’écart des recouvrements et dispositifs de protection.
batteries. Ces dernières produisent des gaz explosifs en  Arrêter le moteur avant d’installer ou brancher l’appareil.
fonctionnement normal et en cours de charge.  Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
pannage, faire retirer les portes, panneaux, recouvrements ou
 Suivre les instructions du fabricant de la batterie lors d’opérations
dispositifs de protection uniquement par du personnel qualifié.
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’-  Pour empêcher tout démarrage accidentel pendant les travaux
informations. d’entretien, débrancher le câble négatif (−) de batterie de la borne.
OM-282374 Page 9
 Ne pas approcher les mains, cheveux, vêtements lâches et outils cisé autrement dans la section maintenance du manuel du
des organes mobiles. moteur).
 Remettre en place les portes, panneaux, recouvrements ou  Si le moteur est chaud et que le liquide doit être vérifié, opérer com-
dispositifs de protection à la fin des travaux d’entretien et avant de me suivant.
mettre le moteur en marche.  Mettre des lunettes de sécurité et des gants, placer un torchon sur
 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la le bouchon du radiateur.
mise en route accidentelle du moteur.  Dévisser le bouchon légèrement et laisser la vapeur s’échapper
 Bloquer le volant moteur pour éviter sa rotation lors d’une avant d’enlever le bouchon.
intervention sur le générateur.
L’utilisation d’un groupe autonome
LES ÉTINCELLES À L’ÉCHAPPEMENT à l’intérieur PEUT VOUS TUER EN
peuvent provoquer un incendie. QUELQUES MINUTES.
 Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.  Les fumées d’un groupe autonome contient du
 Utiliser uniquement un pare-étincelles monoxyde de carbone. C’est un poison invisi-
approuvé − voir codes en vigueur. ble et inodore.
 JAMAIS utiliser dans une maison ou garage, même avec les por-
LES PIÈCES CHAUDES peuvent tes et fenêtres ouvertes.
provoquer des brûlures.  Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
 Ne pas toucher des parties chaudes à mains
nues.
 Prévoir une période de refroidissement avant de L’ACIDE DE LA BATTERIE peut pro-
travailler à l’équipement. voquer des brûlures dans les YEUX et
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- sur la PEAU.
dés et porter des gants de soudage et des vêtements épais pour  Ne pas renverser la batterie.
éviter les brûlures.
 Remplacer une batterie endommagée.
LA VAPEUR ET LE LIQUIDE DE  Rincer immédiatement les yeux et la peau à l’eau.
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures. LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
 Il est préférable de vérifier le liquide de refroi-
dissement une fois le moteur refroidi pour éviter  Ne pas placer l’appareil sur, au-dessus ou à
de se brûler. proximité de surfaces inflammables.
 Toujours vérifier le niveau de liquide de refroidissement dans le  Tenir à distance les produits inflammables de l’échappement.
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même MÉTAL CHAUD provenant du découpage
la mort. ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.

 Ne pas découper ou gouger à proximité de produits inflammables.

 Une installation ou une utilisation incorrecte de cet appareil
pourrait conduire à des dégâts matériels ou corporels. Seul un  Attention aux risques d’incendie: tenir un extincteur à proximité.
personnel qualifié est autorisé à installer, utiliser et entretenir
cet appareil conformément à son manuel d’utilisation, aux normes L’AIR COMPRIMÉ risque de provoquer
industrielles et aux codes nationaux, d’état ou locaux. des blessures ou même la mort.
 Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir  Avant d’intervenir sur le circuit d’air comprimé,
le circuit d’air comprimé de telle sorte que la défaillance couper l’alimentation électrique, verrouiller
d’un composant ne risque pas de provoquer un accident matériel et étiqueter l’appareil, détendre la pression
ou corporel. et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
 Avant d’intervenir sur le circuit d’air comprimé, couper
 Détendre la pression avant de débrancher ou
l’alimentation électrique, verrouiller et étiqueter l’appareil,
de brancher des canalisations d’air.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
 Avant d’utiliser l’appareil, contrôler les composants du circuit d’air
 Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil comprimé, les branchements et les flexibles en recherchant tout
fonctionne. Seul un personnel qualifié est autorisé, et appliquant signe de détérioration, de fuite et d’usure.
les consignes du fabricant.  Ne pas diriger un jet d’air vers soi−même ou vers autrui.
 Ne pas modifier ou altérer le compresseur ou les équipements  Pour intervenir sur un circuit d’air comprimé, porter un équipement
fournis par le fabricant. Ne pas débrancher, désactiver ou de protection tel que des lunettes de sécurité, des gants de cuir,
neutraliser les équipements de sécurité du circuit d’air comprimé. une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
 Utiliser uniquement des composants et accessoires homologués
 Pour rechercher des fuites, utiliser de l’eau savonneuse ou
par le fabricant.
un détecteur à ultrasons, jamais les mains nues. En cas
 Se tenir à l’écart de tout point présentant un danger de pincement de détection de fuite, ne pas utiliser l’équipement.
ou d’écrasement créé par l’équipement raccordé au circuit d’air  Remettre les portes, panneaux, recouvrements ou dispositifs
comprimé. de protection quand l’entretien est terminé et avant de mettre
 Ne pas intervenir sous ou autour d’un équipement qui n’est en marche l’appareil.
soutenu que par la pression pneumatique. Soutenir l’équipement  En cas d’injection d’air dans la peau ou le corps, demander
de façon appropriée par un moyen mécanique. immédiatement une assistance médicale.
OM-282374 Page 10
 détendre la pression et s’assurer que le circuit d’air ne peut être
L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance.
de provoquer des blessures ou même
la mort.  Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
 Ne pas inhaler d’air comprimé. s’il y a lieu, des travaux d’entretien et de dépannage.
 Utiliser l’air comprimé uniquement pour  Remettre en place les portes, panneaux, recouvrements ou
découper ou gouger ainsi que pour l’outillage dispositifs de protection à la fin des travaux d’entretien et avant
pneumatique. de mettre le moteur en marche.

Une PRESSION D’AIR RÉSIDUELLE DES PIÈCES CHAUDES peuvent

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

Les PIÈCES MOBILES peuvent causer

des blessures. LIRE LES INSTRUCTIONS.

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

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

Risque D’INCENDIE OU LE SURCHAUFFEMENT peut

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

LES ÉTINCELLES PROJETÉES

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

OM-282374 Page 11
 LA SORTIE DE RECHARGE et L’EXP-  Réduire le courant ou le facteur de marche avant de poursuivre le
soudage.
LOSION DE LA BATTERIE peuvent  Ne pas obstruer les passages d’air du poste.
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les LES CHARGES ÉLECTROSTATI-
modèles. QUES peuvent endommager les
 Toujours porter une protection faciale, des gants en caoutchouc circuits imprimés.
et vêtements de protection lors d’une intervention sur la batterie.  Établir la connexion avec la barrette de terre
 Arrêter le moteur avant de débrancher ou de brancher des câbles de avant de manipuler des cartes ou des pièces.
batterie, des câbles de chargeur de batterie (le cas échéant) ou de  Utiliser des pochettes et des boîtes antistatiques pour stocker,
batterie d’entretien. déplacer ou expédier des cartes de circuits imprimes.
 Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie. UNE REMORQUE QUI BASCULE peut
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou provoquer des blessures.
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si
l’appareil dispose d’une fonctionnalité de charge de batterie destinée à  Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
cet usage.
 Observer la polarité correcte (+ et −) sur les batteries.  Installer convenablement le poste sur la remor-
 Débrancher le câble négatif (−) en premier lieu. Le rebrancher en que comme indiqué dans le manuel s’y rappor-
dernier lieu. tant.
 Les sources d’étincelles, flammes nues, cigarettes et autres sources
d’inflammation doivent être maintenues à l’écart des batteries. Ces LIRE LES INSTRUCTIONS.
dernières produisent des gaz explosifs en fonctionnement normal et
en cours de charge.  Lire et appliquer les instructions sur les
 Suivre les instructions du fabricant de la batterie lors d’opérations sur étiquettes et le Mode d’emploi avant
une batterie ou à proximité de celle−ci. Voir le manuel de service de l’installation, l’utilisation ou l’entretien de
batterie (indiqué dans Normes de sécurité) pour plus d’informations. l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
 Les opérations de charge de batterie ne doivent être effectuées que
par des personnes qualifiées.  N’utiliser que les pièces de rechange recommandées par le
 Pour enlever la batterie d’un véhicule pour la recharge, débrancher constructeur.
tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour  Effectuer l’installation, l’entretien et toute intervention selon les
éviter un arc, s’assurer que tous les accessoires sont débranchés. manuels d’utilisateurs, les normes nationales, provinciales et de
 Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur l’industrie, ainsi que les codes municipaux.
de batterie pour alimenter un autre circuit électrique basse tension ou
pour charger des batteries sèches. LE RAYONNEMENT HAUTE FRÉ-
 Ne pas charger une batterie gelée. QUENCE (H.F.) risque de provoquer
 Ne pas utiliser de câbles de charge endommagés. des interférences.
 Ne pas charger des batteries dans un espace fermé ou en l’absence
d’une ventilation.  Le rayonnement haute fréquence (H.F.) peut
 Ne pas charger une batterie dont les bornes sont desserrées ou provoquer des interférences avec les équipe-
présentant une détérioration comme par exemple un boîtier ou un ments de radio−navigation et de communica-
couvercle fissuré. tion, les services de sécurité et les ordinateurs.
 Avant de charger une batterie, sélectionner la tension de charge
 Demander seulement à des personnes qualifiées familiarisées avec
correspondant à la tension de la batterie.
des équipements électroniques de faire fonctionner l’installation.
 Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge ne  L’utilisateur est tenu de faire corriger rapidement par un électricien
se touchent pas. qualifié les interférences résultant de l’installation.
 Ranger les câbles de charge à distance du capot, des portes et des  Si le FCC signale des interférences, arrêter immédiatement l’appareil.
pièces mobiles du véhicule.  Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES LIQUIDES PRESSURISÉS peuvent  Maintenir soigneusement fermés les portes et les panneaux des
blesser ou tuer. sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
 Les composants du système d’alimentation interférences éventuelles.
peuvent contenir du carburant sous pression
élevée. LE SOUDAGE À L’ARC risque de
 Avant d’intervenir sur le système d’alimentation de carburant, provoquer des interférences.
arrêter le moteur pour dépressuriser le système.  L’énergie électromagnétique risque de provoquer
 En cas d’injection de tout liquide sous la peau ou dans le corps, des interférences pour l’équipement électronique
solliciter une aide médicale sur le champ. sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
LES FILS DE SOUDAGE peuvent  Veiller à ce que tout l’équipement de la zone de soudage soit com-
provoquer des blessures. patible électromagnétiquement.
 Ne pas appuyer sur la gâchette avant d’en  Pour réduire la possibilité d’interférence, maintenir les câbles de
avoir reçu l’instruction. soudage aussi courts que possible, les grouper, et les poser aussi
 Ne pas diriger le pistolet vers soi, d’autres per- bas que possible (ex. par terre).
sonnes ou toute pièce mécanique en enga-  Veiller à souder à une distance de 100 mètres de tout équipement
geant le fil de soudage. électronique sensible.

L’EMPLOI EXCESSIF peut  Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
SURCHAUFFER L’ÉQUIPEMENT.
 En cas d’interférences après avoir pris les mesures précédentes, il in-
 Laisser l’équipement refroidir ; respecter le fac- combe à l’utilisateur de prendre des mesures supplémentaires telles
teur de marche nominal. que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation
de filtres de ligne ou la pose de protecteurs dans la zone de travail.
OM-282374 Page 12
2-6. Proposition californienne 65 Avertissements
Pour les moteurs diesel :
AVERTISSEMENT : ce produit peut vous exposer à des pro-
duits chimiques tels que le plomb, reconnus par l’État de AVERTISSEMENT : les gaz d’échappement de moteurs diesel
Californie comme cancérigènes et sources de malformations vous exposent à des produits chimiques, reconnus par l’État
ou d’autres troubles de la reproduction. de Californie comme cancérigènes et sources de malfor-
Pour plus d’informations, consulter www.P65Warnings.ca.gov. mations ou d’autres troubles de la reproduction.
 Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
 Si la zone est fermée, diriger l’échappement vers l’ex-
térieur.
 Ne pas modifier ni altérer le système d’échappement.
 Ne pas faire tourner le moteur au ralenti, sauf si nécess-
aire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safe Practice For Occupational And Educational Eye And Face Protec-
is available as a free download from the American Welding Society at tion, ANSI Standard Z87.1, from American National Standards Institute,
http://www.aws.org or purchased from Global Engineering Documents 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
(phone: 1-877-413-5184, website: www.global.ihs.com). site: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding Standard for Fire Prevention During Welding, Cutting, and Other Hot
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Work, NFPA Standard 51B, from National Fire Protection Association,
al Engineering Documents (phone: 1-877-413-5184, website: Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org.)
www.global.ihs.com). OSHA, Occupational Safety and Health Standards for General Indust-
Safe Practices for Welding and Cutting Containers that have Held Com- ry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
bustibles, American Welding Society Standard AWS A6.0, from Global and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Engineering Documents (phone: 1-877-413-5184, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
website: www.global.ihs.com). 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régiona-
ux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
National Electrical Code, NFPA Standard 70, from National Fire Protec- : www.osha.gov).
tion Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
www.nfpa.org and www. sparky.org).
mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, (phone: 301-504-7923, website: www.cpsc.gov).
from Compressed Gas Association, 14501 George Carter Way, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, tional Institute for Occupational Safety and Health (NIOSH), 1600
website:www.cganet.com). Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
Safety in Welding, Cutting, and Allied Processes, CSA Standard www.cdc.gov/NIOSH).
W117.2, from Canadian Standards Association, Standards Sales, 5060 Pour les normes réglementant les systèmes hydrauliques, com-
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS muniquez avec National Fluid Power Association, 6737 West
(phone: 800-463-6727, website: www.csagroup.org). Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian 778-3344, site web : www.nfpa.com).
Standards Association, Standards Sales, 5060 Spectrum Way, Suite Manuel de service de batterie, Battery Council International, 330 North
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
website: www.csagroup.org). 1-312-245-1074, site Web : www.batterycouncil.org).

2-8. Informations relatives aux CEM

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

OM-282374 Page 13
  Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
 Some symbols are found only on CE products.

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

Safe1 2012−05

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe2 2017−04

Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2017−04

Keep your head out of the fumes.

Safe6 2017−04

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012−05

Do not weld on drums or any closed containers.

Safe16 2017−04

Do not remove or paint over (cover) the label.

Safe20 2017−04

OM-282374 Page 14
  Complete Parts List available at www.MillerWelds.com

Do not work on unit if engine is running. Stop engine first.

Safe21 2017−04

Do not smoke while fueling or if near fuel.

Safe22 2017−04

Stop engine before fueling.

Safe23 2017−04

Do not fuel a hot engine.

Safe24 2017−04

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).

Safe25 2012−05

Do not spray water on electrical parts, including Engine Control Unit (ECU).

Safe 118 2014−10

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2017−04

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2017−04

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

Safe91 2017−04

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

OM-282374 Page 15
  Complete Parts List available at www.MillerWelds.com
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

Engine fuel plus flames or sparks can cause fire.

=
Safe45 2012−05

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

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

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

/ + − + −
Safe117 2014−06

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

Safe54 2017−04

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

Safe55 2012−05

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

Safe87 2012−07

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

Safe88 2012−07

3-2. Miscellaneous Symbols And Definitions

 Some symbols are found only on CE products.

A Amperage Seconds Positive

V Voltage
Read Operator’s
Manual
Direct Current
(DC)

Hz Hertz Negative
Alternating
Current (AC)

OM-282374 Page 16
  Complete Parts List available at www.MillerWelds.com

n
Protective Earth Rated Load
Engine
(Ground) Speed

n0
Engine Start Rated No−Load
Single Phase (Engine RPM) Speed

n1
Engine Off
Three Phase (Engine Stop) Rated Idle Speed

Suitable For
Welding In An
Environment With
Increased Risk Of
Idle (Slow)
X Duty Cycle

Electric Shock

Off
Run (Fast)
h Hours

P1max
Engine Belt Maximum Power
Consumption
On
Engine−Driven
Air Compressor 3−Phase
Alternator with
Remote Rectifier
Air Compressor Circuit Breaker
Do Not Switch Supplementary
While Welding Protector
Air Filter
Output
Welding (General)
Call for
Maintenance
Shielded Metal
Arc Welding Previous
(SMAW) Check
Injectors/Pump
Flux Cored Arc
Welding (FCAW)
Check Valve
Clearance Next
Gas Metal Arc
Welding (GMAW)
Certified/Trained
Mechanic
Gas Tungsten Arc Menu
Welding (GTAW) /
Tungsten Inert
Gas (TIG) Spark Arrestor Cancel Function
Welding

Lift Arc TIG Air Cleaner View

Engine Oil Temperature

Enter

Fuel Filter Diagnostics

Engine Coolant Increase Arc Control

Battery (Engine)
U0 Rated No−Load
Voltage (OCV)
USB

Engine
U2 Conventional
Load Voltage
Push Button

Engine I2 Rated Welding

Current
Rotating Knob
And Push Button

OM-282374 Page 17
  Complete Parts List available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the right side. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Weld, Power, And Engine Specifications

 This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Maximum Open-
Rated Output Dual Rated Output Single
Welding Mode Weld Output Range Circuit Voltage
Operator (Each Side) Operator
(Nominal)

20−400A Stick: 400A, 36 VDC, Stick: 800A, 38 VDC,

Dual Operator 100% Duty Cycle 100% Duty Cycle
CC/DC 95
40−800A TIG: 400A, 26 VDC, 100% TIG: 800A, 38 VDC, 100%
Single Operator Duty Cycle Duty Cycle

400A, 34 VDC, 100% Duty 800A, 38 VDC, 100% Duty

CV/DC 13−50V 95
Cycle Cycle

Generator Power Rating Engine Fuel Tank Capacity

Independent of Weld Output

Single-Phase, 4 kVA/kW, 34/17 A,
120/240 V AC, 50/60 Hz
Deutz TD2011L04w Oil-cooled, Four-cylinder,
3-Phase Generator (In addition to standard 25 gal (95 L)
Turbo-charged 63.4 HP Diesel Engine
4 kVA/kW Generator Power) Single-Phase/
Three-Phase, 12/20 kVA/kW, 50/48 A,
120/240 V AC, 50/60 Hz

4-3. Air Compressor Specifications

Compressor Model And Air Output At Effective Working Safety Relief

Factory Pressure Setting
Type Pressure Valve Rating

60 scfm (1.7 m3 min−1),

Ingersoll Rand CE55 G
100 psi (690 kPa), 125 psi (862 kPa) 150 psi (1034 kPa)
Rotary Screw
100% Duty Cycle

4-4. Environmental Specifications

A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06

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

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

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

OM-282374 Page 18
  Complete Parts List available at www.MillerWelds.com
4-5. Dimensions, Weights, And Operating Angles
Dimensions
53.75 in. (1365 mm)
Height
(to top of exhaust)

28.5 in. (724 mm) G

(mtg. brackets turned in)
Width
30.75 in. (781 mm)
(mtg. brackets turned out)
Depth 69.5 in. (1765 mm)
! Do not exceed tilt angles or engine could
A 69.5 in. (1765 mm) be damaged or unit could tip.

B* 57.9 in. (1470 mm) ! Do not move or operate unit where it could
tip.
C* 46.375 in. (1178 mm)
A
D* 11.5625 in. (294 mm) B C
E 27.5 in. (699 mm)
F 1 in. (25 mm)
30°
G 29.8125 in. (757 mm)
H 30°
9/16 in. (14 mm) Dia.
H
4 Holes 20°
D 20°
* With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight E 907763

No fuel: 2020 lb ( kg) 802 161-A

W/fuel: 2195 lb ( kg)

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

4-6. Duty Cycle And Overheating

1 100% Duty Cycle

1
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.

 This unit is rated for welding at

400 amperes continuously in
dual operator mode or 800 am-
peres continuously in single
operator mode.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

OM-282374 Page 19
  Complete Parts List available at www.MillerWelds.com
4-7. Volt-Ampere Curves
The volt-ampere curves show the
A. Stick Mode minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
100 other settings fall between the
curves shown.

80
DC VOLTS

Parallel Mode
60

Dual Operator
40

20

0
0 100 200 300 400 500 600 700 800

DC AMPERES
B. TIG Mode

100

80
DC VOLTS

Parallel Mode
60

40
Dual Operator

20

0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
C. MIG Mode

100

80
DC VOLTS

60
Parallel Mode

40
Dual Operator
20 Minimum Settings

0
0 100 200 300 400 500 600 700 800 900

DC AMPERES

259 678-B

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4-8. AC Generator Power Curves
The AC power curve shows the
A. Single Phase 4 kW generator power in amperes.

280

260
AC VOLTS

240

220

200

180
0 10 20 30 40
AC AMPERES

B. Single Phase 12 kW
140 280
135 270
130 260
125 250
AC VOLTS

120 240
115 230
110 220
105 210

100 200
95 190
90 180
0 10 20 30 40 50 60 70 80 90 100
AC AMPERES

C. Three Phase 20 kW
280

260
AC VOLTS

240

220

200

180
0 10 20 30 40 50 60
AC AMPERES
253 021-A / 254 115-A / 254 114-A

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

4.00
3.75
3.50
No Air Output
3.25
3.00
2.75 With Air Output
2.50
2.25
US Gal./Hr.

2.00
Dual Weld Mode
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800

DC WELD AMPERES AT 100% DUTY CYCLE

268 071-A

Notes

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

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

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

Location/Mounting

Welding Bolting
Unit In Unit In
Place 2 Place 3
2

OR

OR

Tools Needed: 1 1

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

 Go to MillerWelds.com for more ! Do not weld on base. Welding on

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

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5-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

rot_grnd2 2018−01 − 800652-D

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

5-3. Installing Exhaust Pipe

! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in. Ref. 907 535-1 / 907 535−3 / Exhaust3

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5-4. Connecting The Battery

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

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

5-5. Using The Battery Disconnect Switch

! Stop engine.
1 Battery Disconnect Switch
The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.

907 634−2

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  Complete Parts List available at www.MillerWelds.com
5-6. Engine Prestart Checks
NOTICE − Follow run-in procedure in
engine manual. If unburned fuel and oil
collect in exhaust pipe, see Section 14.

Full

Diesel

Full

907763 / 907 634−2

 Check all engine fluids daily. NOTICE − Diesel engines in Miller equip-
ment are meant to operate optimally at mod-
Oil
After fueling, check oil with unit on level sur-
 Automatic warning and shutdown indi- erate to rated load. Using light or no load for
face. If oil is not up to full mark on dipstick,
cators are displayed on the Engine Dis- extended periods of time may cause wet-
add oil (see engine maintenance label).
play. See Section 13 for engine display stacking or engine damage.
information. Follow run-in procedure in engine manual.  To improve cold weather starting:
If unburned fuel and oil collect in exhaust
Engine must be cold and on a level surface. pipe, see Section 14. Keep battery in good condition. Store
Automatic shutdown system stops engine if Fuel battery in warm area.
oil pressure is too low or engine tempera-
ture is too high. NOTICE − Do not use gasoline. Gasoline Use fuel formulated for cold weather
will damage engine. (diesel fuel can gel in cold weather).
 This unit has a low oil pressure shut- Add fresh diesel fuel before starting (see Contact local fuel supplier for fuel in-
down switch. However, some condi- engine maintenance label for fuel specifica- formation.
tions may cause engine damage before tions). Leave filler neck empty to allow room
the engine shuts down. Check oil level for expansion. Use correct grade oil for cold weather
often and do not use the oil pressure (see engine maintenance label or en-
shutdown system to monitor oil level. Engine stops if fuel level is low. gine manual).

OM-282374 Page 26
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5-7. Connecting To Weld Output Terminals

! Stop engine.
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your ma-
chine.
Tools Needed:
3/4 in.  Do not place anything between weld
1 2 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
6
3 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
4 weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
5

803 778-B

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-282374 Page 27
  Complete Parts List available at www.MillerWelds.com
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.
Welder A (Left) Side Welder B (Right) Side

1
1

258 836

! Stop engine. 1 Electrode Holder Cables For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
NOTICE − Do not exceed machine duty 2 Work Cables
Positive (+) terminals and electrode holder
cycle.
For Stick/TIG welding Direct Current Elec- cables to Negative (−) terminals.
 Use Dual Operator mode for CC and trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
CV welding (see Section 6-2).
trode holder cables to Positive (+) ter-  Be sure Process Selector switches
See Section 5-15 for proper cable size. minals. are set correctly. See Section 6-4.

OM-282374 Page 28
  Complete Parts List available at www.MillerWelds.com
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

1
2
1

258 836

! Stop engine. work cable must be able to carry combined nect other end of work jumper cable to
! Failure to properly size and connect weld output of both modules (see Section Welder A (left) Negative (−) terminal.
weld cables may cause excessive 5-15 for proper cable size).
Connect electrode holder cables to Positive
heat and start a fire, or damage your NOTICE − Do not exceed machine duty (+) terminals.
machine. cycle.
NOTICE − When making weld connections For Stick/TIG Direct Current Electrode
with a common work cable, connect weld  Use Dual Operator mode for CC and Negative (DCEN), connect common work
cable of adequate size between Negative CV welding (see Section 6-2). cable and work jumper cable to Welder B
(−) weld output terminals, and connect a (right) Positive (+) terminal. Connect other
1 Electrode Holder Cables
single weld cable of adequate size from end of work jumper cable to Welder A (left)
Welder B (right) Negative (−) terminal to the 2 Work Jumper Cable Positive (+) terminal.
workpiece. 3 Common Work Cable Connect electrode holder cables to Nega-
NOTICE − When using these connections For Stick/TIG welding Direct Current Elec- tive (−) terminals.
as a common work terminal, all connec- trode Positive (DCEP), connect common
tions must be of the same polarity. work cable and work jumper cable to  Be sure Process Selector switches are
NOTICE − For common work connection, Welder B (right) Negative (−) terminal. Con- set correctly. See Section 6-4.

OM-282374 Page 29
  Complete Parts List available at www.MillerWelds.com
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

1
1

258 836

! Stop engine. 1 Wire Feeder Cables For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
NOTICE − Do not exceed machine duty
2 Work Cables cables to Positive (+) terminals and wire
cycle.
feeder cables to Negative (−) terminals.
 Use Dual Operator mode for CC and For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
CV welding (see Section 6-2).
cables to Negative (−) terminals and wire  Be sure Process Selector switches are
See Section 5-15 for proper cable size. feeder cables to Positive (+) terminals. set correctly. See Section 6-4.

OM-282374 Page 30
  Complete Parts List available at www.MillerWelds.com
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

258 836

! Stop engine. weld output of both modules (see Section mon work cable and work jumper cable to
5-15 for proper cable size). Welder B (right) Negative (−) terminal.
! Failure to properly size and connect Connect other end of work jumper cable to
weld cables may cause excessive NOTICE − Do not exceed machine duty
Welder A (left) Negative (−) terminal.
heat and start a fire, or damage your cycle.
machine.
 For common work connection, work Connect wire feeder cables to Positive (+)
terminals.
NOTICE − When making weld connections cable must be able to carry combined
with a common work cable, connect weld weld output of both CC weld output ter-
For MIG and FCAW Direct Current Elec-
cable of adequate size between Negative minals (see Section 5-15 for proper
trode Negative (DCEN), connect common
(−) weld output terminals, and connect a cable size).
work cable and work jumper cable to Weld-
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the  Use Dual Operator mode for CC and er B (right) Positive (+) terminal. Connect
CV welding (see Section 6-2). other end of work jumper cable to Welder
workpiece. A (left) Positive (+) terminal.
1 Wire Feeder Cables
NOTICE − When using these connections Connect wire feeder cables to Negative (−)
as a common work terminal, all connec- 2 Work Jumper Cable
terminals.
tions must be of the same polarity. 3 Common Work Cable
NOTICE − For common work connection, For MIG and FCAW welding Direct Current  Be sure Process Selector switches
work cable must be able to carry combined Electrode Positive (DCEP), connect com- are set correctly. See Section 6-4.

OM-282374 Page 31
  Complete Parts List available at www.MillerWelds.com
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.
Welder A (Left) Side Welder B (Right) Side

3
2

258 836

! Stop engine. For Stick/TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect work Electrode Positive (DCEP), connect work
NOTICE − Do not exceed machine duty
cable to Negative (−) terminal and elec- cable to Negative (−) terminal and wire
cycle.
trode holder cable to Positive (+) terminal. feeder cable to Positive (+) terminal.
 Use Dual Operator mode for CC and For Stick/TIG Direct Current Electrode For MIG and FCAW Direct Current Elec-
CV welding (see Section 6-2).
Negative (DCEN), connect work cable to trode Negative (DCEN), connect work
See Section 5-15 for proper cable size. Positive (+) terminal and electrode holder cable to Positive (+) terminal and wire feed-
1 Electrode Holder Cable cable to Negative (−) terminal. er cable to Negative (−) terminal.

2 Wire Feeder Cable  Be sure Process Selector switches  Be sure Process Selector switches
3 Work Cables are set correctly. See Section 6-4. are set correctly. See Section 6-4.

OM-282374 Page 32
  Complete Parts List available at www.MillerWelds.com
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

3
2

Ref. 251 340-A / Ref. 802 292-A

! Stop engine. 5-15 for proper cable size). Connect electrode holder cable to one Pos-
! Failure to properly size and connect itive (+) terminal.
NOTICE − Do not exceed machine duty
weld cables may cause excessive cycle. Connect wire feeder cable to remaining
heat and start a fire, or damage your Positive(+) terminal.
machine.  Use Dual Operator mode for CC and  Be sure Process Selector switches are
NOTICE − When making weld connections CV welding (see Section 6-2).
set correctly. See Section 6-4.
with a common work cable, connect weld 1 Electrode Holder Cable
cable of adequate size between Negative For Direct Current Electrode Negative
(−) weld output terminals, and connect a 2 Wire Feeder Cable (DCEN), connect common work cable and
single weld cable of adequate size from work jumper cable to Welder B (right) Posit-
Welder B (right) Negative (−) terminal to the 3 Work Jumper Cable ive (+) terminal. Connect other end of work
workpiece. jumper cable to Welder A (left) Positive (+)
4 Common Work Cable
terminal.
NOTICE − When using these connections For Direct Current Electrode Positive
as a common work terminal, all connec- Connect electrode holder cable to one
(DCEP), connect common work cable and Negative (−) terminal, and wire feeder
tions must be of the same polarity. work jumper cable to Welder B (right) Neg- cable to remaining Negative (−) terminal.
NOTICE − For common work connection, ative (−) terminal. Connect other end of
work cable must be able to carry combined work jumper cable to Welder A (left) Nega-  Be sure Process Selector switches are
weld output of both modules (see Section tive (−) terminal. set correctly. See Section 6-4.

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  Complete Parts List available at www.MillerWelds.com
5-14. Making Single Operator CC Weld Connections

 Direct Current Electrode Positive

(DCEP) connections are shown.
Welder B (right) Terminals
Inactive In Single Operator Mode

Welder A (Left) Side

Tools Needed:

3/4 in.

1
2

258 836

! Stop engine.  Use Single Operator mode for CC weld- For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
ing only. Welder B weld output terminals
to Negative (−) terminal and electrode hold-
NOTICE − Do not exceed machine duty are disabled in Single Operator mode.
(see Section 6-2). er cable to Positive (+) terminal.
cycle.
For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to Posit-
 Welder B (right) weld output terminals  See Section 5-15 for proper cable size. ive (+) terminal and electrode holder cable
are disabled in Single Operator mode. to Negative (−) receptacle.
Connect only to Welder A (left) termi- 1 Electrode Holder Cable
nals for Single Operator mode opera-  Be sure Process Selector switch is set
tion. 2 Work Cable correctly. See Section 6-4.

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  Complete Parts List available at www.MillerWelds.com
5-15. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding 10 − 100% Duty Cycle
Duty Cycle Duty Cycle
Amperes AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
700 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120)
800 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120) 4x4/0 (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08

5-16. Weld Output Terminals

! Turn off power before connecting
to weld output terminals.
! Do not use worn, damaged, un-
dersized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

1
2

output term1 2015−02

OM-282374 Page 35
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5-17. Connecting To Remote 14 Receptacle

Socket* Socket Information

 Not all models have contactor control. See description of front panel controls and
circuit diagram.

A 24 volts AC. Protected by supplementary protector.

24 VOLTS AC
B Contact closure to A completes 24 volt AC contactor
*The remaining sockets control circuit.
are not used.
C Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or TIG mode.

REMOTE D Remote control circuit common.

 Accessories depend OUTPUT
on unit capabilities. CONTROL E DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.

F Current feedback: 1 volt per 100 amperes.

OR
H Voltage feedback: 1 volt per 10 arc volts.

K Chassis common.
GND

NEUTRAL G Circuit common for 24 volt AC circuit.

Rmt14_1 2010−04

Notes

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5-18. Connecting To The Air Compressor

! Stop engine and release air pres-

sure before servicing compressor.

Open Position
1

Closed Position

907763

! Air pressure is present at air shutoff Be sure valve is in open position when us- The air compressor will not start if still under
valve whenever Engine Display on ing air compressor. pressure. If air compressor is turned off,
front panel indicates air pressure. The compressor runs and air pressure is wait for air pressure to bleed off (about 20
available whenever the engine is running seconds) before turning air compressor on
1 3/4 in. NPT Air Pressure
and the front panel Compressor switch is again.
Fitting
moved to the On position (see Section 6-2).
2 Air Shutoff Valve Run engine at weld/power speed for maxi-
mum air compressor output. Compressor  Using the air compressor does not sig-
Connect air hose with 3/4 in. NPT fitting (not output is reduced when engine is running at nificantly affect weld or generator pow-
supplied) to air shutoff valve. idle speed. er output.

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SECTION 6 − OPERATING WELDER/GENERATOR
6-1. Front Panel Controls (See Section 6-2)

10 6 11 7 12 8

4 5 3 14 1

13

15

907763 / 277078

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

Engine Starting Controls  To access Arc Control setting, push and Other Receptacles
1 Engine Control Switch hold Adjust control for 1 second, then re- 9 USB Receptacle
Use switch to start engine, select engine lease. Rotate counterclockwise to set Allows software updates from a USB drive
speed, and stop engine. softer arc control. Rotate clockwise to set (see Section 6-11). A summary file of record-
stiffer arc control. Push Adjust control in ed data from the unit will be saved to a USB
In Run position, engine runs at weld/power
and release to save Arc Control setting. drive that is inserted (see Section 6-12).
speed. In Run/Idle position, engine runs at
Arc Control setting will time out after 5
idle speed with no generator power or weld Indicator Lights
seconds of inactivity.
load, and weld/power speed with load ap-
10 Setup Light
plied.
 To access Service Menu, push and hold Illuminates when in the Service Menu.
NOTICE − Diesel engines in Miller equipment Adjust control for 5 seconds, then re-
are meant to operate optimally at moderate to 11 In Use Light
lease. See Section 6-5 for Service Menu
rated load. Using light or no load for extended operation. Service Menu will time out af- Illuminates when connected to an ArcReach
periods of time may cause wetstacking or en- ter 5 seconds of inactivity. accessory.
gine damage.
12 Arc Control Light
2 Engine Display Weld Meters
Illuminates when in the Arc Control settings.
See Section 13 for engine display informa-
tion.
 Weld meters also work in combination to 13 Welder Selector Switch
display troubleshooting error codes (see NOTICE − Do not switch under load.
Weld Controls Section 8-11).
3 Remote Control Receptacle Use switch to select Dual Operator or Single
6 DC Voltmeter Operator welding mode.
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC. Voltmeter displays preset voltage (GMAW/ Place switch in Welder A/Welder B (dual op-
FCAW welding) with contactor off, and actual erator) position for CC and CV output from
When a remote control is connected to the
output voltage with the contactor on. Voltme- Welder A (left) and Welder B (right) weld out-
Remote receptacle, the Auto Remote Sense
ter displays voltage at the weld output termi- put terminals. Control the weld output from the
(ARS) feature automatically switches volt-
nals, but not necessarily the welding arc due terminals on each side using the weld con-
age/amperage control to the remote control
to resistance of cable and connections. trols on that same side.
(see Section 6-10).
With remote control connected, weld output is To set voltage, turn Process/Contactor switch Place switch in Welder A (single operator)
determined by a combination of front panel to GMAW or FCAW position. Turn V/A control position for weld output from Welder A (left)
and remote control voltage/amperage set- until desired voltage is displayed on Volt- weld output terminals only.
tings. meter. When welding is finished, voltmeter
displays average weld voltage and then de-
 Welder B (right) weld output terminals are
If no remote control is connected to the Re- disabled in Single Operator mode. Con-
mote receptacle, the front panel Voltage/Am- faults to preset voltage.
nect only to Welder A (left) terminals for
perage control adjusts voltage and amper- 7 DC Ammeter Single Operator operation.
age.
Compressor Controls
Ammeter displays preset amperage (Stick
 If a remote device connected to Remote and TIG only) when not welding, and actual 14 Air Compressor Switch
Receptacle is faulty or is disconnected output amperage when welding.
during operation, the meters display Use switch to turn air compressor on and off.
CHEK REMT (see Section 8-11). Clear To set amperage, turn Process/Contactor Air pressure is present at the compressor air
fault by stopping and restarting the unit or switch to Stick or TIG position. Turn V/A con- shutoff valve whenever the compressor is
by turning Process/Contactor switch to trol until desired amperage is displayed on running. The compressor shuts off when the
another position. Ammeter. When welding is finished, ammeter engine stops. To use air, the compressor must
displays average weld amperage and then be turned on each time the engine is started.
4 Process/Contactor Switch
defaults to preset amperage. The air compressor will not start if still under
See Section 6-4 for Process/Contactor
pressure. If air compressor is turned off, wait
switch information. 8 Arc Control Meter
for air pressure to bleed off (about 20 sec-
5 Adjust Control/Select Button Displays current Arc Control setting. Default onds) before turning air compressor on again.
Adjust Control value for all processes is 0. Arc Control set- 15 Air Shutoff Valve
With Process/Contactor Switch in any SMAW tings adjust: DIG for SMAW processes, Auto
Stop for GTAW processes, and inductance ! Air pressure is present at valve when-
or GTAW process, turn Adjust control to ad- ever Air Pressure display (part of en-
just preset amperage. With Process/Contac- for FCAW and GMAW processes. For softer
settings, the LEDs to the left of the star illumi- gine display, see Section 13) indicates
tor switch in any FCAW or GMAW process, air pressure.
turn Adjust control to adjust preset voltage. nate. For stiffer settings, the LEDs to the right
of the star illuminate. No Arc Control settings Close valve to stop air flow when connecting
Select Button are accessible for GTAW Remote and CAC-A or changing tools or air hoses (see Section
Push the control to use as Select button. processes. See Section 6-6. 5-18).

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6-3. Engine Starting Sequence

Wait to Start/Preheating

Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
1 Compressor Oil 0 Compressor Oil 495

NOTICE − Do not use ether or other start- The Wait to Start display appears when the Once this message clears, the engine can
ing fluids. Engine Control switch is placed in the Run be started.
or Run/Idle position. Glow plugs function
 If engine does not start, let engine automatically according to ambient tem-
Turn Engine Control switch to Start. Re-
lease Engine Control switch when engine
come to a complete stop before at- perature. The operator needs to pause at
tempting restart. starts.
either switch position while the engine con-
To Start: To Stop: turn Engine Control switch to Off
troller goes through the preheat sequence.
position.
1 Wait to Start/Preheating Display

Notes

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  Complete Parts List available at www.MillerWelds.com
6-4. Process/Contactor Switch
1 Process/Contactor Switch
! Weld output terminals are
energized when Process/
Contactor switch is in an
Electrode Hot position and
the engine is running.
Use switch to select weld process
and weld output on/off control
(see table below).
Place switch in Remote On/Off
Switch Required positions to turn
weld output on and off with a de-
1
vice connected to the Remote re-
ceptacle.
Place switch in Electrode Hot
positions for weld output to be on
whenever the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Sec-
tion 6-9).

Ref. 277070-A

Process/Contactor Switch Setting Typical Process Applications (DC Only)

MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not
Output On – GMAW/FCAW (MIG)
require a control cable back to the welder/generator.

Output On – FCAW-S (Electrode FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that
Negative) does not require a control cable back to the welder/generator.

Output On − SMAW (STICK XX18

OUTPUT ON

Stick welding with or without a remote amperage control. Strike an arc to start welding.
and STICK XX10)
Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
Output On – GTAW (Lift-Arc TIG) welder/generator to aid arc start. Can be used with or without a remote control. Auto
Crater option can be enabled/disabled using the Service Menu (see Section 6-5).
Output On – CAC-A (Air Carbon Arc
Gouging with or without a remote amperage control. Strike an arc to start gouging.
Gouging)
REMOTE ON/OFF REQUIRED

High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with re-
Remote ON/OFF Required - GTAW
mote control allows remote On/Off and Amperage control. Another typical application is a
(Remote TIG)
simple TIG rig with a remote control device.

Remote ON/OFF Required - SMAW Stick welding with RHC-14 control allows remote On/Off and Amperage control. This can
(Remote Stick) help eliminate accidental arc strikes.

Remote ON/OFF Required - GMAW/ MIG solid wire and dual shield flux core using a constant speed feeder. Use feeders with
FCAW (Remote MIG) 14-pin remote voltage control, or use a Spoolmatic 30A with WC24 control.

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  Complete Parts List available at www.MillerWelds.com
6-5. Service Menu
1 Adjust Control/Select Button
Press and hold control for 5 seconds,
then release to access the Service
Menu. Rotate the knob to scroll
through the menu items. Press and
release the control to access the op-
1 tions and information within each
menu item.
Rotate the control counterclockwise
to decrease the value or select NO/
OFF. Rotate the control clockwise to
increase the value or select YES/
ON.
Press and release control to save se-
lection. After 5 seconds of inactivity,
the menu will time out and the selec-
tion will not be saved.

277078

Menu Item Selectable Item Description

Option(s)
HOT STRT LIMT OFF Disables Hot Start option.
(Only accessible in SMAW LIMT 1.25 Sets Hot Start current limit, selectable between 1.25 and 2.0 (0.25 increments) in
processes) SMAW XX10 and SMAW Remote.

LIMT 1.50 Sets Hot Start current limit, selectable between 1.5 and 3.0 (0.5 increments) in
SMAW XX18.
DIG RNGE 50 - 150 Sets current limit above preset amperage between 50 and 150 amps.
AUTO CRTR ATCR ON Enables Auto Crater option.
(Only accessible in GTAW
processes) ATCR OFF Disables Auto Crater option.

VRD* VRD ON Enables VRD (Voltage Reducing Device) option, lowering open-circuit voltage.
VRD OFF Disables VRD (Voltage Reducing Device) option.
SOFT WARE −− Displays the current revision of firmware installed.
FACT RSET* RSET YES Resets all settings to factory defaults.
RSET NO All settings remain at previous settings.
*On Side A, user must first select whether to apply settings to Side A only or to both sides.

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6-6. Arc Control Settings
 Arc Control is not active when the Process/Contactor switch is in the following positions:
Electrode Hot − CAC-A (Air Carbon Arc Gouging)
Remote ON/OFF GTAW (Remote TIG)

 Miller recommends Hobart filler metals.

Process/Contactor Switch Arc Control
SOFT Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT -12

 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance)

(1 to 25)
STIF 12
Voltage sensing feeder

SOFT Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)

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

STIFF Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13
(1 to 25) electrodes.

STOP Auto-Crater off (see Section 6-5). More sensitive Auto-Stop

(−5 to −1)

 (0) Starting point.

STOP Less sensitive Auto-Stop

(1 to 5)

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.

STOP Auto Crater on (see Section 6-5). More sensitive Auto-Crater

(−5 to −1) initiation

 (0) Starting point

STOP Less sensitive Auto-Crater initiation

(1 to 5)

SOFT
(−25 to −1)

 (0) Starting point

STIFF
(1 to 25)

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  Complete Parts List available at www.MillerWelds.com
Process/Contactor Switch Arc Control
SOFT Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT -12
 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance).

(1 to 25)
STIF 12
Starting point for dual shield flux core, vertical overhead
Wire feeder connects to
Remote receptacle STIF 25

6-7. Dynamic Dig Settings

Process/Contactor Switch Arc Control
SOFT Starting point for 3/32 rod
(−25 to −1)
SOFT -15
 (0) Starting point for XX10 electrode/open root vertical down joint

STIFF Stiffer, more rapidly responding arc

(1 to 25)

Dig Range
DIG Starting point for 3/32 rod
(50)
DIG RNGE 65
(100) Starting point for downhill pipe (factory default)

DIG RNGE 115

(150)

Arc Control
SOFT Flat or horizontal welds with XX18 electrode or 3/32 rod with short
(−25 to −1) weld cables

SOFT -15
 (0) Starting point for XX10, XX11, XX13, XX14, XX24, and XX22
electrodes

STIFF
(1 to 25)

Dig Range
DIG Starting point for 3/32 rod
(50)
DIG RNGE 65
Starting point for XX18 electrode

DIG RNGE 75
(100) Starting point for downhill pipe (factory default)

DIG RNGE 115

(150)

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  Complete Parts List available at www.MillerWelds.com
6-8. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
1
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted too
high. If electrode sticks to
2 workpiece, use a quick twist to free
it.

6-9. Lift-Arct TIG With Auto-Stopt And Auto-Cratert

Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc Select Lift-Arc at Process/Contac-
tor switch.
1 2 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 work-
Arc End With Auto-Stop piece contamination by using
Auto-Crater or Auto-Stop to end
1 2 3 the arc.

 See Section 6-5 to adjust

Auto-Stop and Auto-Crater.
Arc End With Auto-Stop:
1 While welding.
2 Lift torch to start Auto-Stop.
Arc stops.
3 Move torch back down to
maintain gas coverage and
prevent contamination.
Arc End With Auto-Crater:
OR
 Remote control is not needed
when using Auto-Crater.
Arc End With Auto-Crater 1 While welding.
2 Lift torch slightly to start
1 2 3 4 Auto-Crater end (current is
reduced).
3 Lower torch. Weld current
ramps down.
4 Shielding gas continues until
shut off.
 Miller recommends Hobart
filler metals.

WM Marketing

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  Complete Parts List available at www.MillerWelds.com
6-10. Voltage/Amperage Control With 14-Pin Remote Accessory
1 Remote Receptacle
Connect optional remote control to
receptacle.
2 3  When a remote control is con-
nected to the Remote recep-
tacle, the Auto Remote Sense
feature automatically switches
voltage/amperage control to
the remote control. When a de-
vice is connected to the Re-
mote receptacle, remote volt-
age/amperage control is al-
ways available regardless of
the position of the Process/
Contactor switch.
2 Voltmeter
3 Ammeter
1

CC Welding

In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
85 205
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding

Connect Remote Set V/A Control

Control To Remote To Desired Maximum
Turn Remote Control On. Ad- Weld Output Using Weld
Receptacle just Optional Remote Meters
Set TIG or STICK Process Control to 100%

CV Welding Max (205 A DC)

28
Output On: Voltmeter toggles
between preset and actual
output when not welding, ac-
tual voltage while welding.
0 Min (20 A DC)

Adjust Optional Remote

Remote On/Off Required: Ammeter Shows Zero Control to desired
Voltage shown is preset. weld output

Connect Remote Adjust Optional Remote

Control To Remote Control to desired
Receptacle weld output

Set WIRE Process

0774 / Ref.272 446-B / Ref. 907 695

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  Complete Parts List available at www.MillerWelds.com
6-11. Updating Software

Obtain the latest firmware to be loaded When the machine has powered up, if valid During the download, the left meter display
from MillerWelds.com. files exist on the flash drive, the user is indicates the active download with ALLC,
prompted to confirm the start of the down- ALLW, AL C, or AL W. The right meter dis-
Copy the desired firmware to an approved load. The Voltmeter/Ammeter display play indicates the percentage of the down-
USB flash drive (see Section 11-1). reads: AL? NO. load completed with a number from 0 to
100.
Confirm by rotating the Adjust Control/Se-
With the machine turned off, insert the
lect button clockwise to select YES. Then When the update has completed success-
flash drive into the USB receptacle on the
press the Select button. fully, the machine restarts.
front of the machine. Turn the Engine Con-
trol switch to the Run or Run/Idle position.  After the update has started, do not Failures are indicated on the meter display.
power down or remove the flash drive Correction of failed updates depends on
 Do not start the engine. until the update is complete. what type of failure occurred.

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  Complete Parts List available at www.MillerWelds.com
6-12. Summary File
1 Summary File
Each time a USB stick is inserted
1 in the USB receptacle, a summa-
ry file is saved to the USB stick as
SummaryFile.txt.
“USB ACC” will display as the file
is written. File is complete when
display no longer shows “USB
ACC.”
The summary file provides diag-
nostic and weld information.

OM-282374 Page 48
  Complete Parts List available at www.MillerWelds.com
6-13. Fuel/Hour Gauge Descriptions

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  Complete Parts List available at www.MillerWelds.com
6-14. Associating ArcReach Devices (ArcReach Models Only)

! Stop engine.
NOTICE − Do not exceed machine duty cycle.
Associating ArcReach Device To Engine Driven Welder/Generator
Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection
diagrams.
The welder/generator has the ability to associate automatically with an ArcReach device at power up. The Process/Contactor switch must
be set to an Output ON mode to associate with an ArcReach device.
See the ArcReach device Owner’s Manual to associate the device to the welder/generator.
When the association process is complete, the In Use light will be illuminated. Depending on the capabilities of the ArcReach device, the
Process/Contactor switch, Adjust Control/Select button, and Arc Control adjustment may be overridden.

The following ArcReach accessories are compatible with this welder/generator:

ArcReach Stick/TIG Remote ArcReach SuitCase Feeders ArcReach Smart Feeder

For Stick Or TIG Welding For MIG Or FCAW Welding For Advanced Wire Processes

When welder/generator is associated When welder/generator is associated When welder/generator is associated

with Stick/TIG Remote: with Suitcase X-TREME ArcReach with Smart Feeder, all controls switch
SMAW processes: Amperage, feeder, voltage and wire feed settings to the feeder, and the display reads
Electrode Type, and Arc Control are adjusted on the feeder. SMRT ACC.
settings are adjusted on the remote.  When using an ArcReach device,
GTAW and CAC-A processes: engine speed is always
Amperage settings are adjusted on the weld/power speed.
remote.

274460-A / 266206-D

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  Complete Parts List available at www.MillerWelds.com
6-15. Operating Oil Pan Heater
1 Oil Pan Heater Plug
Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Heater rated at 300 watts.
! Do not run engine while oil
pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
power source when engine oil is
warm to eliminate possibility of oil
coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.
! The area near the oil pan
heater gets hot.
Disconnect plug to turn off heater.

Oil heater1 2018−01

Notes

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  Complete Parts List available at www.MillerWelds.com
6-16. Optional Air Dryer Operation
The air dryers blow out (purge) mois-
ture and debris when the air compres-
sor is being used. The air dryer heaters
operate whenever the welder/genera-
tor is running.
See the supplied air dryer Owner’s
Manual for air dryer maintenance and
service information.

 When battery access is required,

disconnect and remove the air
dryer assembly as described in
Section 8-12.
1 Circuit Breaker CB14
CB14 protects the dryer heaters from
damage due to overload. If CB14
opens, the heaters do not work and the
dryer does not discharge moisture in
cold weather.
Press button to reset circuit breaker
2 CB14.

 When a circuit breaker opens, it

usually indicates a more serious
problem exists. Contact a Factory
Authorized Service Agent.
Start engine, and turn on air compres-
sor. Check fittings for air leaks and
tighten fittings if necessary.
2 Timer Control LED
Verify dryer solenoid is functioning by
listening for dryer canisters to purge, or
by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.

907763 / 803 228 / 803 229

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  Complete Parts List available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Export Auxiliary Power Receptacles

8 7 5
6

4
9

10

1 2 12 11

Ref. 264 998

1 110 V 16 A AC Receptacle RC1 ! Test GFCI monthly. See Section 7-2 10 Supplementary Protector CB8
for GFCI information and for reset-
2 220 V 16 A AC Receptacle RC3 ting and testing procedures. CB8 protects GFCI2 and RC2 from over-
load. If supplementary protector opens, the
Receptacles supply 50/60 Hz single-phase 6 Supplementary Protector CB1 receptacles do not work. Press button to re-
power. CB1 protects RC5 from overload. If supple- set.
mentary protector opens, the receptacle 11 220 V 16 A AC Receptacle RC4
3 Supplementary Protector CB7 does not work. Place switch in On position
to reset. 12 110 V 16 A AC Receptacle RC2
CB7 protects GFCI1 and RC1 from over-
load. If supplementary protector opens, the 7 400 V 30 A 3-Phase Receptacle RC5 Receptacles supply 50/60 Hz single-phase
receptacles do not work. Press button to re- Receptacle supplies 50/60 Hz three-phase power.
set. power Maximum combined output of all standard
! Use GFCI protection when operating 8 Supplementary Protector CB5 receptacles is 4 kVa/kW.
auxiliary equipment. If unit does not CB5 protects the auxiliary power winding
have GFCI receptacles, use from over current. If CB5 opens, the 110 volt
 At least once a month, run engine at
GFCI-protected extension cord. Do receptacles and 220 volt receptacles do not weld/power speed and press test but-
not use GFCI receptacles to power work. Place switch in up position to reset. ton to verify ELCB1 is working properly.
life support equipment.
9 Earth Leakage Circuit Breaker ELCB1  If a supplementary protector or circuit
! Unplug power cord before attempt- breaker continues to open, contact
ELCB1 protects receptacles RC3 and RC4
ing to service accessories or tools. Factory Authorized Service Agent.
from overload and earth leakage fault. If cir-
4 110 V 20 A AC Receptacle GFCI1 cuit breaker opens, the receptacles do not
work. Place switch in On position to reset  Generator power decreases as weld
5 110 V 20 A AC Receptacle GFCI2 circuit breaker. output increases.

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

 Alternate location for red

and green indicator LEDs.

2
5

 Orientation of receptacle may be different in other applications.

RotGFCI1 2017-10

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

OM-282374 Page 54
 8-1. Maintenance Label
 Complete Parts List available at www.MillerWelds.com

NOTICE − The total initial oil fill requires approximately

18 qt (17 L). Service oil fill is 11 qt (10.4 L)
Check engine dipstick as filling. Do not overfill.
SECTION 8 − MAINTENANCE

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

8-2. Routine Maintenance

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

 = Check  = Change = Clean

= Replace Reference
* To be done by Factory Authorized Service Agent
Every See engine Section 5-6
8 FUEL
WATER manual for fuel
Hours
specifications.

 Primary Fuel Filter  Fuel Level  Oil Level Oil, Fuel Spills
= Clean unit exterior, in-
cluding stainless steel, fre-
quently to prevent rust and
corrosion.
 Coolant Level
Every Section 8-7
100
Hours

Battery Terminals  Air Cleaner Hoses  Air Cleaner Element Weld Terminals
Every Engine
250 1/2 in.
(13 mm) Manual
Hours

Unreadable Labels  Fan Belt Tension Cooling System  Spark Arrestor
Every NOTICE − Change engine Section 8-9,
500 oil and filter after initial 50 and Engine
Hours to 75 hours of use. Manual
See engine manual for oil
specifications.
 Oil  Oil Filter  Fuel Filters 
Weld Cables
Every Section 8-4,
FUEL
1000 OR 8-9, and
Hours Engine
Manual
SLUDGE
 Slip Rings* Inside Unit Valve Clearance* Drain Sludge

Brushes*
Every NOTICE − Use extended
2000 life coolant only.
Hours See engine manual for
coolant specifications.

Coolant
Every Every
3000 6000
Hours Hours or
5 Years
Injectors* 
Engine Timing Belt

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8-3. Cleaning Unit
Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust.

NOTICE − Use of a power washer is acceptable; however, cover or avoid electrical parts and the Engine Control Unit (ECU) located on the upper
left side of the center upright.

8-4. Checking Generator Brushes

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

1
Replace Damaged Brushes

GenBrush1 2018−01 / Ref 190823

8-5. Battery Replacement

! Stop engine.
1 Battery Locator Bracket
Mounting Holes
Access battery as shown in Section
5-4. Disconnect battery.
View From Top Of Unit
Remove J-bolts securing battery
Larger Battery and remove battery.
Smaller Battery
Battery locator brackets can be
moved to accommodate batteries
of different physical sizes.
Install and secure replacement bat-
tery.
! Connect negative (−) battery
cable last.

1
Tools Needed:

255 858

8-6. Battery Maintenance

Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.

OM-282374 Page 57
  Complete Parts List available at www.MillerWelds.com
8-7. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
4 ing and the possibility of filter damage
makes cleaning a risk. Consider the
1 risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
2 ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
the safety element after servicing the pri-
Optional mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
customer supplied)
3 Service Indicator Window
4 Service Indicator Reset Button
5 6 7 8
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Optional
5 Housing
9
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm) ! Do not clean housing with air
from element. hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
Blow Inspect (dust ejector down).

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

8-8. Engine Speed Adjustment

 Engine functions are controlled by the engine ECU. Tampering with the engine ECU may void engine warranty. Contact engine Factory Authorized
Service Agent for engine adjustments.

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8-9. Servicing Fuel And Lubrication Systems

4 5

Tools Needed: 6

Ref. 907763 / Ref. 907 634−2

! Stop engine and let cool. To replace fuel filters: To drain sludge from fuel tank:
! After servicing, start engine and
check for fuel leaks. Stop engine, Turn filter counterclockwise. Remove filter. ! Beware of fire. Do not smoke and
tighten connections as necessary, keep sparks and flames away from
and wipe up spilled fuel. Apply thin coat of fuel to gasket on new filter. drained fuel. Dispose of drained fuel
1 Oil Filter Fill filter with fuel. Install filter and turn clock- in an environmentally-safe manner.
wise. For primary fuel filter, reconnect water Do not leave unit unattended while
2 Oil Drain Valve And Hose draining fuel tank.
sensor. Bleed air from fuel system accord-
3 Oil Fill Cap ing to engine manual.
4 Primary Fuel Filter ! Properly lift unit and secure in a level
5 Secondary Fuel Filter Inspect fuel line, and replace if cracked or position. Use adequate blocks or
worn. stands to support unit while drain-
6 Fuel Tank Sludge Drain Valve ing fuel tank.
To change oil and filter: Close doors.
Route oil drain hose and valve through hole Attach 1/2 ID hose to drain valve. Put metal
in base. See engine manual and engine To reset service reminder intervals shown container under drain, and use screwdriver
maintenance label for oil/filter change in- on the Engine Display, see Sections 13-12 to open sludge drain valve. Close valve
formation. and 13-13. when sludge has drained. Remove hose.

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8-10. Engine/Generator Overload Protection

8
7

3
4

6
5
7

907763

! Stop engine. CB2 opens, the engine does not crank. 7 Supplementary Protector CB14

 When a supplementary protector, cir- 3 Fuse F1 Air dryer overload protection, see Section
cuit breaker or fuse opens, it usually in- 4 Fuse F2 6-16.
dicates a more serious problem exists. F1 and F2 protect the stator exciter winding 8 Supplementary Protector CB15
Contact Factory Authorized Service from overload. If F1 opens, weld and gen-
Agent. erator power is low or stops entirely. If F2 Compressor overload protection, see Sec-
opens, weld output is low or stops entirely. tion 9-4.
 See Section 9-4 for air compressor 4 kVA/kW generator power is still available.
overload protection. 9 Circuit Breaker CB10 (Not Shown)
See Section 6-16 for air dryer overload 5 Supplementary Protector CB3
CB10 protects the engine battery circuit. If
protection. 6 Supplementary Protector CB4 CB10 opens, the engine will not crank.
1 Supplementary Protector CB9/CB29 CB3 protects the engine weld control cir- CB10 automatically resets when the fault is
cuit. If CB3 opens, weld output stops, corrected.
CB9 and CB29 protect the 24 volt AC out-
meters will be blank; however, generator
put to remote receptacles. If CB opens, 10 Circuit Breaker CB16 (Not Shown)
power is still available.
weld output and 24 volt output to remote re-
ceptacle stops. CB4 protects the field flashing circuit. If CB16 protects the glow plug circuit. If
CB4 opens, the generator may not excite at CB16 opens, the glow plug will not operate.
2 Supplementary Protector CB2
start-up and weld and generator power out- CB16 automatically resets when the fault is
CB2 protects the engine control circuit. If put may not be available. corrected.

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8-11. Voltmeter/Ammeter Error Displays

IGBT TEMP
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. Display Example

 When an error is displayed, normally weld output has stopped but generator power output may be okay.
 To reset error displays, stop unit and then restart. See below to reset CHEK REMT display.

Error Display Description

CHEK REMT Indicates a remote device connected to the Remote Receptacle may be faulty. CHEK REMT is also displayed whenever a
remote device has been connected to the Remote Receptacle and then disconnected. Clear fault by stopping and restarting
the unit, or by pressing and releasing the Adjust Control/Select button. If problem continues, have Factory Authorized Service
agent check the remote device and main control board PC1/PC21.

IGBT 1SHT Indicates the thermistor in IGBT module 1 has shorted. Have Factory Authorized Service Agent check unit.

IGBT 1OPN Indicates the thermistor in IGBT module 1 is open. Have Factory Authorized Service Agent check unit.

IGBT 2SHT Indicates the thermistor in IGBT module 2 has shorted. Have Factory Authorized Service Agent check unit.

IGBT 2OPN Indicates the thermistor in IGBT module 2 is open. Have Factory Authorized Service Agent check unit.

IGBT TEMP Indicates an IGBT module has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle.
Keep engine access door closed when running unit to maintain proper cooling airflow past module. Allow unit to cool before
restarting. If problem continues, have Factory Authorized Service Agent check unit.

MAX POWR Engine power limit exceeded, causing weld output to be temporarily reduced. Error clears after 5 seconds.

S/W ERR Software version mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service
Agent check unit.
S/W BLD Software build mismatch occurred. Reload software update. If error does not clear, have Factory Authorized Service Agent
check unit.
COMM LOSS Indicates a communication loss between control boards. Parallel mode will not function. Error can be cleared by pressing
and releasing the Adjust Control/Select button. Unit can operate in dual operator mode only after clearing error. If error
does not clear, have Factory Authorized Service Agent check unit.

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8-12. Removing Optional Air Dryer For Service
 Follow this procedure whenev-
er the air dryer must be re-
moved to gain access to the
battery.
1 Air Line
2 Timer Control Cable
3 Air Dryer Heater Plug
4 Solenoid LED
Disconnect air line from dryer as-
sembly bottom inlet.
Disconnect heater cable from bot-
tom of air dryer assembly.
Loosen hardware securing battery
access panel to rear panel. Careful-
ly pull access panel/air dryer as-
sembly away from unit rear panel.
Support dryer assembly to relieve
strain on timer control cable.
3 Disconnect battery negative (−)
cable. When service is complete,
reconnect battery negative (−)
2 cable.
Reinstall battery access panel/air
dryer assembly. Reconnect air dry-
er heater cable.
Reconnect air line to dryer bottom
inlet.
Final-tighten all hardware, and
air line and air dryer fittings.
Start engine, and turn on air com-
pressor. Check fittings for air leaks
and tighten fittings if necessary.
Verify dryer solenoid is functioning
by listening for dryer canisters to
purge, or by checking solenoid
1 LED. LED lights at start-up and ev-
ery two minutes when the canisters
automatically purge.

803 511

OM-282374 Page 62
  Complete Parts List available at www.MillerWelds.com
SECTION 9 − AIR COMPRESSOR MAINTENANCE

9-1. Air Compressor Maintenance Label

 The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment.
The compressor will require service more often if used in dirty, humid conditions.

Notes

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9-2. Routine Air Compressor Maintenance
 See Section 8 for engine/generator maintenance information.

Recycle air
compressor
fluids.
! Stop engine before maintaining.

 Service air compressor more often if used in severe conditions.

 = Check  = Change = Clean
= Replace Reference
* To be done by Factory Authorized Service Agent
Every Section 9-5
8
Hours

Spills  Oil Level

Every Section 9-3
250
Hours

Unreadable Labels  Belt Tension  Air Cleaner Hoses Air Filter Element

Worn or Damaged Air/Oil Cooling System
Hoses
Every Section 9-5
500
Hours

 Oil  Oil Filter

Every Section 9-5
1000
Hours

 Air/Oil Separator

OM-282374 Page 64
  Complete Parts List available at www.MillerWelds.com
9-3. Servicing Compressor Air Cleaner
! Stop engine.
1
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
damaged element is not covered by the
warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
NOTICE − If you decide to clean the pri-
mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
the safety element after servicing the pri-
mary element three times.
1 Compressor Air Cleaner
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
2 3 4 5 indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element (Optional)

Optional 4 Primary Element

5 Cover
6
6 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.
! Do not clean housing with air
hose.

Keep nozzle Clean primary element with compressed

2 in (51 mm) air only.
from element. Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).

Blow Inspect

aircleaner1 5/15*−907 634-2 / ST-153 929-B / ST-153 585 / Ref. S-0698-B

OM-282374 Page 65
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9-4. Compressor Overload Protection
! Stop engine.

 When a circuit breaker or fuse

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

 See Section 8-10 for engine/gener-

ator overload protection.
1 Circuit Breaker CB15
Circuit breaker CB15 protects the air
compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.
Press button to reset breaker.

907763

OM-282374 Page 66
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9-5. Servicing Air Compressor

Tools Needed: 7/8, 15/16 in.

Air Compressor Assembly Right Side

7
5

Too
High
2

Full Full

1
3
Too
Low

907763 / 255 862-A

! Stop engine and let cool. Wait 60 sec- To change compressor oil and filter: Add recommended oil until oil level indicator
onds for system pressure to drop be- shows system is full (see compressor mainte-
fore changing oil.  The engine oil drain and compressor oil nance label for oil specifications). Reinstall oil
drain hoses are located together in the fill cap. Tighten cap with wrench.
1 Air Compressor Oil Filter base. Be sure to select the correct hose
when draining compressor oil. To replace secondary air/oil separator:
2 Secondary Air Compressor Air/Oil  Be sure o-rings at oil drain and oil fill fit-
Separator tings are in place before reinstalling caps. Loosen nut securing oil scavenge tube on
separator base. Lift oil scavenge tube from
Drain compressor oil while compressor is still separator. Turn filter counterclockwise. Re-
3 Air Compressor Oil Drain Hose warm.
w/Removable Cap move filter.
Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Re- Apply thin coat of oil to gasket on new filter.
4 Air Compressor Oil Fill Cap
move cap from oil drain hose and drain oil into Install filter and turn clockwise. Reinstall oil
a suitable container. Reinstall oil drain hose scavenge tube.
5 Air Compressor Oil Level Indicator cap. Tighten cap with wrench.
6 Air Compressor Primary Air/Oil Remove filter by turning filter counterclock- Start engine, run air compressor, and check
Separator Tank wise. Remove filter. Apply thin coat of oil to for oil leaks.
gasket on new filter. Install new filter and turn
7 Oil Scavenge Tube clockwise until tight. ! Stop engine.

OM-282374 Page 67
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9-6. Adjusting Compressor Air Pressure

Check compressor air pressure using

air pressure gauge known to be accu-
rate. If necessary, adjust air pressure
as follows:
Tools Needed: 1 Screw
5/16, 3/8 in. Loosen jam nut securing screw. Turn
screw clockwise (increase pressure)
or counterclockwise (decrease) until
pressure is 125 psi (862 kPa).

 Maximum weld output is reduced

if compressor air pressure is set
above 125 psi (862 kPa).
Tighten nut.
2 Pressure Relief Valve
Pressure relief valve opens and re-
leases pressure at 150 psi (1034
kPa). The pressure relief valve is not
adjustable.

Air Compressor Assembly Left Side

907763 / 255 862-A / Ref: 803 228

OM-282374 Page 68
  Complete Parts List available at www.MillerWelds.com
SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting

 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). Also see Engine Information Display
to assist in troubleshooting engine related problems (see Section 13).

A. Welding

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch in an Electrode Hot position, or place switch in a Remote On/Off Re-
okay at AC receptacles. quired position and connect remote contactor to Remote receptacle (see Sections 5-17).

Reset supplementary protector CB3 (see Section 8-10).

Reset supplementary protector CB9 and/or CB29 (see Section 8-10). Check for faulty remote device
connected to Remote receptacle.

Check and secure connections to Remote receptacle (see Section 5-17).

Check fuse F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
brushes and slip rings, weld excitation circuit, and the rotor.

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

Reset supplementary protector CB4 (see Section 8-10).

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.

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

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Check position of Voltage/Amperage Adjust control.

Have engine Factory Authorized Service Agent check engine speed.

Have Factory Authorized Service Agent check voltage feedback circuit.

Low weld output. Check position of Voltage/Amperage Adjust control.

Have engine Factory Authorized Service Agent check engine speed.

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.

Low open-circuit voltage. Have engine Factory Authorized Service Agent check engine speed.

Check position of Process/Contactor switch.

No remote fine amperage or voltage Check and secure connections to Remote receptacle (see Section 5-17).
control.

Repair or replace remote control device.

Have Factory Authorized Service Agent check current sensing devices, and connections.

Constant speed wire feeder does not Reset supplementary protector CB9 or CB29 (see Section 8-10).
work.

Check and secure connections to Remote receptacle (see Section 5-17).

Repair or replace wire feeder.

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Trouble Remedy

Low CV weld output. Increase Voltage/Amperage Adjust Control setting.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Process/Contactor switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control and field current
regulator board.

B. Standard Generator Power

Trouble Remedy

No generator power output at AC Reset receptacle supplementary protectors. Reset GFCI receptacle.
receptacles; weld output okay.

Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
integrated rectifiers SR1 and SR2, resistor R3, and capacitor C6.

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

Check fuses F1 and F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check integrated rectifiers SR1 and SR2, capacitor C6, and the rotor.

Reset supplementary protector CB4. Have Factory Authorized Service Agent check integrated rectifier
SR1 .

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

High output at generator power AC Have engine Factory Authorized Service Agent check engine speed.
receptacles.

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

Low output at generator power AC Have engine Factory Authorized Service Agent check engine speed.
receptacles.

Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
integrated rectifier SR2, resistor R3, and capacitor C6.

Have Factory Authorized Service Agent check brushes and slip rings.

C. Three-Phase Generator Power

Trouble Remedy
No or low output at three-phase gener- Reset supplementary protector CB1 (see Section 7-1).
ator/receptacle RC5.

Have engine Factory Authorized Service Agent check engine speed.

Have Factory Authorized Service Agent check brushes and slip rings.
High output at three-phase generator/ Have engine Factory Authorized Service Agent check engine speed.
receptacle RC5.

Erratic output at three-phase generator/ Have Factory Authorized Service Agent check brushes and slip rings.
receptacle RC5.

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D. Engine

Trouble Remedy
Engine will not crank. Supplementary protector CB2 open. Reset CB2.

Check battery connections and tighten if necessary. Check battery, and replace if necessary.

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

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check control relay CR5 and Engine Control switch S1.

Engine cranks but does not start. Check fuel level.

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

Have Factory Authorized Service Agent check control relay CR5. Have engine Factory Authorized
Service Agent check fuel pump and fuel system.

Air in fuel system. See engine manual.

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

Have Factory Authorized Service Agent check control relay CR5.

Engine hard to start in cold weather. Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.

Use correct grade oil for cold weather (see maintenance label and engine manual).

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

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 8-7 and 8-9).

See engine manual.

Battery discharges between uses. Turn Engine Control switch off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Have engine Factory Authorized Service Agent check speed control.
weld speed.

Engine does not run at idle speed. Have Factory Authorized Service Agent check control relay CR4/CR24.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 14).
wetstacking occurs.

E. Air Compressor

Trouble Remedy
Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If
pressure at air shutoff valve. compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor
on again.

Reset supplementary protector CB15 (see Section 9-4).

Check compressor belt tension. Be sure correct belt is used and is properly installed.

Verify secondary air/oil filter is not plugged. Replace air/oil separator.

Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pres-
sure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.

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Trouble Remedy
Air compressor stops after short period Check compressor oil level (see Section 9-5). Automatic shutdown stops compressor if compressor tem-
of operation. perature is too high.

Clean debris from radiator. Automatic shutdown stops compressor if compressor temperature is too high.

Low air pressure. Check for leaks in air lines and hoses.

Adjust compressor air pressure (see Section 9-6).

Check air compressor air cleaner (see Section 9-3).

Have Factory Authorized Service Agent check compressor for rated output.

High air pressure. Adjust compressor air pressure (see Section 9-6).

Be sure control line is connected at regulator valve and inlet valve.

Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195117).
moisture in compressed air.

Oil in air from compressor. Check compressor oil level (see Section 9-5). If oil level is too high, system becomes saturated with oil.

Change compressor air/oil separator (see Section 9-5).

Check connections of control lines (see air compressor circuit diagram in Section 12).

Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.

Oil in compressor air cleaner. Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.

SECTION 11 − PARTS LIST

11-1. Recommended Spare Parts
Dia. Part
Mkgs. No. Description Quantity
. . . . . . . . . . . . . . . . . . . . 276418 . . USB Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 262459 . . Kit, Filters Deutz (2.9l4) Engine (Includes)
. . . . . . . . . . . . . . . . . . . . 192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 255765 . . . . Filter, Fuel Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 255764 . . Filter, Fuel Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246991 . . Filter Kit, Ingersoll Rand (Ce55 G1) (Includes)
. . . . . . . . . . . . . . . . . . . . 206745 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206747 . . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 253944 . . Belt, Micro-v 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 925 Crk 195 Rsv Gp 31 Maint Free . . . . . . . . . . . . . . . . . 1
♦Optional

OM-282374 Page 72
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Notes

OM-282374 Page 73
 SECTION 12 − ELECTRICAL DIAGRAMS

Figure 12-1. Circuit Diagram For Welder/Generator

OM-282374 Page 74
 281933-C

OM-282374 Page 75
 SECTION 13 − ENGINE INFORMATION DISPLAY
 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

13-1. Display Layout And Controls

1 Engine Information Display
2 Engine Control Switch
3 Function Buttons
4 Yellow LED
5 Red LED
The Engine Information Display
turns on whenever the Engine Con-
trol switch is in either Run or Run/
Idle with the engine not running.

 When starting the engine,

1 pause Engine Control switch in
Run or Run/Idle position for
several seconds. The engine
controller initiation sequence
must occur. If glow plugs are on
4 5 (automatically determined by
ambient temperature), also
wait until the initial Wait to Start
3 2 message on the display is
cleared (see Section 13-4).
Function buttons are used to navi-
gate through menus, increase/de-
crease, and select (see Section
13-2).
The yellow LED lights as part of se-
quences used to alert the operator
to errors or conditions that will affect
operation, such as low fuel.
The red LED lights as part of a shut-
down sequence, such as when fuel
is too low or oil pressure is too low
to continue operation without dam-
aging the engine.
There are two display types: 6-Up
and 1-Up. The default 6-Up display
shows six values at once. The 1-Up
display shows one value on the
screen. See Sections 13-5 and
13-6.

MurphyDisplay 2018−01 / 258 833-D

13-2. Function Buttons

Function Button
Previous Next Menu/Cancel View Enter/Diagnostic
6-Up Display None None Menu Go to 1-Up Engine Diagnostics
1-Up Display Previous Next Menu Go to 6-Up Engine Diagnostics

OM-282374 Page 76
13-3. RPM Signal Failed Display
1 RPM Signal Failed Display
If the operator places the Engine
Control switch in the Run/Idle or
Run position and does not start the
engine, a timer starts. If this condi-
tion exists for 30 minutes or longer,
the RPM signal failed message ap-
1 pears. Place Engine Control switch
in Off position to reset.

RPM SIGNAL FAILED

Hide

13-4. Service Reminder Screen

Wait to Start/Preheating 2
1

Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
Compressor Oil 0 Compressor Oil 495

 Glow plugs turn on automatically as de- switch position while the engine controller
goes through the preheat sequence. Once
a few seconds. It can also be found as a
1-up screen (see Section 13-7).
termined by ambient temperature.
this message clears, the engine can be The 6-Up Display then appears as the de-
Compressor oil information appears
only on models with air compressor. started. fault. The engine can be started when the
1 Wait to Start/Preheating Display 2 Service Reminder Display 6-Up Display appears.
The Wait to Start display appears when the The Service Reminder display shows ser- If the Enter/Diagnostic function button is
Engine Control switch is in the Run or Run/ vicing intervals in hours counting down pressed while in this display, the DM2 dia-
Idle position and glow plugs are functioning. from engine manufacturer recommended gnostic screen appears. (see Section
The operator needs to pause at either service intervals. This display appears for 13-11).

OM-282374 Page 77
13-5. 6-Up Display

1
0 PSI 0.0 H 0 PSI 0.0 H
9
3

32 F 0% 32 F 0%
8
4

0 RPM 0 VDC 0 PSI 0 VDC

6 7
5
n/min

1 6-Up Display With Engine RPM 2 6-Up Display With Air Compressor 4 Engine Coolant Temperature
Pressure (Models With Air 5 Engine RPM
This is the default screen configuration. If Compressor)
6 Compressor Air Pressure
the operator wants to toggle to the 1-Up The air compressor must be on and air
pressure must be available for this display 7 Battery Voltage
Display, press the View function button.
The Oil Pressure 1-Up Display appears to appear. 8 Fuel Level
(see Section 13-6). 3 Engine Oil Pressure 9 Engine Hourmeter

13-6. Getting To 1-Up Display

1 View Function Button
From 6-Up Display, press the
View function button to go to 1-Up
Display.
2 1-Up Oil Pressure Display
0 PSI 0.0 H 45 60 To go to the next display, press the
Next function button. To return to
30 75 the 6-Up Display, press the View
0%
32 F
15 90 function button.

0 105
0 RPM 0 VDC
0 PSI
n/min
2
Oil Pressure

OM-282374 Page 78
13-7. 1-Up Displays
1 1-Up Machine Hours Display
To go to the next display, press the
Next function button. To return to
previous display, press the Previ-
1 ous function button. To return to
the 6-Up Display, press the View
function button.

0H
Machine Hours

15 18
12
9
125 6
100 150 3
75
50
175
200 0 0V
25 225
250 Battery Potential
0F
Coolant Temperature
125
100
75

100 50
75 25
50 0 0%
25 Percent Load@RPM
0 0%
Fuel Level

Engine Oil
1000 1500
500 2000
0H
n/min

2500 Service Reminders

0 RPM
Engine Speed

OM-282374 Page 79
13-8. 1-Up Compressor Displays
1 Air Compressor Pressure
1-Up Display
To increment to the next display,
press the Next function button. To
1 return to previous display, press the
Previous function button. To return
to the 6-Up Display, press the View
function button.
80 120
 Air Pressure display does not
40 160 appear if the air pressure input
is less than 50 PSI.
200
0 PSI
Air Pressure

0H
Compressor Oil Compressor Hours
0H
Engine Oil
0H
Service Reminders

OM-282374 Page 80
13-9. Fuel Level Warnings
 Fuel level warnings are generat-
ed by sensors at the fuel tank. All
engine warnings that are dis-
played are generated by the en-
gine controller (see Sections
0 PSI 0.0 H 13-10 and 13-11).
1 6-Up Display
2 1-Up Fuel Level Display
1 3 Low Fuel Warning

32 F 0% The low fuel warning indicator ap-

pears and begins to flash when fuel
level reaches 10%. It continues to
flash until fuel level falls to 0%.
4 Yellow LED
0 RPM 0 VDC The yellow LED begins to flash when
the low fuel warning appears. It con-
tinues to flash until 0% is reached.
5 Red LED
The red LED turns on and stays lit
when fuel level reaches 0%. The en-
gine will shut down.
6 No Fuel Display
This display appears at engine shut-
down. Turn Engine Control switch to
3 Off, refuel, and restart.

100
2
75
50

25
0

Fuel Level

4 5

NO FUEL

Hide

OM-282374 Page 81
13-10. Warning or Shutdown Display
1 Oil Pressure Display
2 Fault Warning Indicator
The warning symbol appears on the
display when an engine condition
approaches a shutdown condition.
45 60 3 Fault Shutdown Indicator
30 75 The shutdown symbol appears on
the display when a severe engine
1 15 90 2 fault can cause shutdown.
3
105 The 6-up or 1-up screen with fault
0 PSI indicator is shown briefly and
automatically advances to the
fault display.
Oil Pressure 4 Fault Display
5 Level Of Fault
6 Indicates Number Of Faults
7 Suspect Parameter Number
8 Failure Mode Identifier
The SPN and FMI numbers are
generated by the engine controller
according to the J1939 standard.
4
Typical faults are listed in Table
13-1.
5 9 Diagnostic Description
6
10 Occurrence Count
For non−critical faults, the number
0 of 0 Warning of occurrences can accumulate
8
7 11 Previous Function Button
SPN: 0 FMI 0
12 Next Function Button
9 13 Hide Function Button
Dm1. DiagnosticString
Non−critical faults can be hidden.
14 Acknowledge Function Button
(Ack)
10 To acknowledge the fault and ad-
OC: 0 vance the display to the 1-up or
6-up display, press the Ack function
button and then the Hide function
button.
Prev Next Hide Ack
 The condition that caused the
warning or shutdown must be
11 14 remedied before operation can
continue.

12 13

1 of 1 Warning

SPN: 100 FMI 1

Low oil pressure warning threshold
exceeded

OC: 1

Prev Next Hide Ack

OM-282374 Page 82
 Table 13-1. Fault Descriptions

 This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized
Service Agent.

SPN FMI Description of Fault

Tier 3 or Tier 4 Interim Engines

100 2 Low oil pressure; warning threshold exceeded

110 2 High coolant temperature; warning threshold exceeded

Tier 4 Final Engines

94 1 Low fuel pressure; warning threshold exceeded

100 1 Low oil pressure; warning threshold exceeded

110 0 High coolant temperature; warning threshold exceeded

111 1 Coolant level too low

168 2 High battery voltage; warning threshold exceeded

174 0 High low fuel temperature; warning threshold exceeded

175 0 High oil temperature; warning threshold exceeded

13-11. Engine Diagnostic Display

 Engine diagnostic codes are
for use by the engine Factory
Authorized Service Agent only.
Attempting engine repair may
1 void engine warranty.
2
1 Diagnostic Display
2 Number Of Faults
0 of 0 Engine Diagnostics
4 3 Suspect Parameter Number
3 4 Failure Mode Identifier
SPN: 0 FMI 0
The SPN and FMI numbers are
5 generated by the engine controller
Dm2. DiagnosticString according to the J1939 standard.
5 Diagnostic Description
6 Requesting/Ok
6 7 Requesting appears on the display
Ok OC: 0 as the display communicates with
the engine controller. Once all diag-
nostic codes are available, Ok ap-
Get pears on the display.
Prev Next Hide Faults 7 Occurrence Count
For non−critical faults, the num-
8 11 ber of occurrences of each fault
can accumulate.
8 Previous Function Button
9 Next Function Button
9 10 10 Hide Function Button
Non−critical faults can be hidden.
11 Get Faults Function Button

OM-282374 Page 83
13-12. Main Menu Access Code
1 Access Code Display
An access code is required to gain
access to the main menu. This dis-
play appears whenever the Menu/
Cancel function button is pressed
while in the 1-Up or 6-Up display
1 ENTER PASSWORD 2 Access Code (Password)
The factory set access code is
2 1000. This access code is not pro-
grammable and cannot be
0000 changed.
3 Increase Number Function
Button
4 Go to Next Number Function
Button
Use the increase function button to
increase the value underlined. Use
4
the > function button to move to the
+ > Cancel Enter next digit.
3 5
5 Cancel Function Button
6 6 Enter Function Button

13-13. Main Menu Options − Resetting Hours At Oil Change

1 Main Menu
2 Cursor
3 Scroll Function Buttons
1 Use scroll function buttons to move
cursor.
Brightness 0% 4 Select Function Button
Contrast 0 When the cursor is in desired posi-
2 tion, press Select function button to
Units English go to sub-menu.
Reminders  5 Service Reminders Display
Move cursor to select engine or
OEM compressor and press Select func-
Version tion button. The appropriate
Change Oil display appears.
Stored Codes 6 Reset Function Button
Language English Press the Reset function button to
reset Remaining Hours after chan-
4 ging oil.
3

Change Engine Oil

Service Reminder IntervalRemaining

Engine Oil  500 0
Compressor Oil 500 490

Modify Reset Cancel

6

OM-282374 Page 84
13-14. Main Menu Options: Brightness, Contrast, And Units
1 Main Menu
2 Cursor
3 Scroll Function Buttons
2 Use scroll function buttons to move
1 cursor.
4 Select Function Button
When the cursor is in desired posi-
Brightness  0% tion, press Select function button to
go to sub-menu.
Contrast 0
5 Brightness Menu Display
Units English Use scroll function buttons to in-
Reminders crease or decrease display
brightness. When desired per-
OEM centage is reached, press Select
function button.
Version
6 Contrast Menu Display
Stored Codes Use scroll function buttons to in-
Language English crease or decrease display con-
trast (lightness/darkness). Con-
4 trast range is 0 to 175. Viewing
angle affects appearance of dis-
play. When desired contrast is
reached, press Select function
button.
7 Units Menu Display
Use scroll function buttons to scroll
through choices:
3 English (PSI, F)
5
Bar (Bar, C)
Kpa (Kpa, C)
Brightness  0%
When desired units configuration
is reached, press Select function
button.

Contrast  0 7
Units  English

OM-282374 Page 85
13-15. Main Menu Options − Reminders
1 Main Menu
2 Cursor
3 Scroll Function Buttons
Use scroll function buttons to move
1 2 cursor.
4 Select Function Button
When the cursor is in desired posi-
tion, press Select function button to
Brightness 0% go to sub-menu.
Contrast 0 5 Service Reminders Display
Units English Move cursor to select engine or
compressor and press Select func-
Reminders  tion button. The appropriate
Change Oil display appears.
OEM
6 Reset Function Button
Version
Press the Reset function button to
Stored Codes reset Remaining Hours after chan-
ging oil.
Language English
7 Modify Function Button
4 NOTICE − The service interval can
be modified. Shorter service inter-
vals may be appropriate during
heavy use or in certain environ-
ments (such as dusty or extreme
temperatures). Lengthening ser-
vice intervals is not recommended
and could result in voiding engine
5 warranty.
3
8 Increase Number Function
Button
9 Go to Next Number Function
Button
Service Reminder IntervalRemaining Use the increase function button to
Engine Oil  500 0 increase the value underlined. Use
the > function button to move to the
Compressor Oil 500 490 next digit.
10 Cancel Function Button
11 Enter Function Button

Change Engine Oil

Change Engine Oil

000000H

+ > Cancel Enter 11

8

Modify Reset Cancel

6

7
9 10

OM-282374 Page 86
13-16. Main Menu Options − OEM, Version, Stored Codes, And Language
1 Main Menu
2 Cursor
3 Scroll Function Buttons
Use scroll function buttons to move
cursor.
1 2 4 Select Function Button
When the cursor is in desired posi-
tion, press Select function button to
go to sub-menu.
Brightness  0% 5 OEM Menu Option
Contrast 0 This menu option is for Factory Au-
thorized Service Agents only and is
Units English password protected.
Reminders 6 Version Menu Display
OEM The information in this display may
5 be requested by a Factory Author-
Version ized Service Agent during
troubleshooting.
Stored Codes
7 Stored Codes
7 Language English
Stored codes can also be accessed
4 when the initial Service Reminder
8 display appears as the engine con-
troller is initiating (see Sections
13-4 and 13-11).
8 Language Menu Display
Use scroll function buttons to
scroll through choices: English,
French, Italian, Spanish, and
3 Brazilian Portuguese. When de-
sired language is reached, press
Select function button.

Configuration 0.0.0.0
Bootloader 00.00. 00.00
Firmware 00.00. 00.00
Part Number XX−XX−XXXX

Version 

OM-282374 Page 87
 SECTION 14 − RUN-IN PROCEDURE
run_in2 2014−10

NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

14-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welder/Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
2
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.
1

OM-282374 Page 88
14-2. Run-In Procedure Using Load Bank Or Resistance Grid

2
1

+
3 6

S-0683 / S-0684

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

OM-282374 Page 89
 SECTION 15 − AIR COMPRESSOR TABLES

15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters

Orifice Diameter (in) And Free Air Flow (CFM)

Gauge Pressure (psi)
1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4
1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85
2 0.038 0.153 0.342 0.607 1.36 2.43 5.42 9.74
3 0.046 0.188 0.471 0.750 1.68 2.98 6.71 11.9
5 0.059 0.242 0.545 0.965 2.18 3.86 8.71 15.4
10 0.084 0.342 0.77 1.36 3.08 5.45 12.3 21.8

15 0.103 0.418 0.94 1.67 3.75 6.65 15.0 26.7

20 0.119 0.485 1.07 1.93 4.25 7.7 17.1 30.8
25 0.133 0.54 1.21 2.16 4.75 8.6 19.4 34.5
30 0.156 0.632 1.40 2.52 5.6 10.0 22.5 40.0
35 0.173 0.71 1.56 2.80 6.2 11.2 25.0 44.7

40 0.19 0.77 1.71 3.07 6.8 12.3 27.3 49.1

45 0.208 0.843 1.9 3.36 7.6 13.4 30.3 53.8
50 0.225 9.14 2.05 3.64 8.2 14.5 32.8 58.2
60 0.26 1.05 2.35 4.2 9.4 16.8 37.5 67.0
70 0.295 1.19 2.68 4.76 10.7 19.0 43.0 76.0

80 0.33 1.33 2.97 5.32 11.9 21.2 47.5 85.0

90 0.364 1.47 3.28 5.87 13.1 23.5 52.5 94.0
100 0.40 1.61 3.66 6.45 14.5 25.8 58.3 103.0
110 0.43 1.76 3.95 7.00 15.7 28.0 63.0 112.0
120 0.47 1.90 4.27 7.58 17.0 30.2 68.0 121.0

130 0.50 2.04 4.57 8.13 18.2 32.4 73.0 130.0

140 0.54 2.17 4.87 8.68 19.5 34.5 78.0 138.0
150 0.57 2.33 5.2 9.20 20.7 36.7 83.0 147.0
175 0.66 2.65 5.94 10.6 23.8 42.1 95.0 169.0
200 0.76 3.07 6.90 12.2 27.5 48.7 110.0 195.0

OM-282374 Page 90
15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At
70-90 P.S.I.G.
MISCELLANEOUS Percent Use Factor And MISCELLANEOUS Percent Use Factor And
PORTABLE Compressed Air Consumption (CF) PORTABLE Compressed Air Consumption (CF)
TOOLS 9 sec 15 sec 21 sec 1 min TOOLS 9 sec 15 sec 21 sec 1 min

Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring Tool, Large 3.6 6.0 8.4 24

Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13

Screwdriver,
#2 to #6 Screw 1.8 3.0 4.2 12 Rammers, Medium 5.1 8.5 11.9 34

Screwdriver,
#6 to 5/16” Screw 3.6 6.0 8.4 24 Rammers, Large 6.0 10.0 14.0 40

Tapper, to 3/8” 3.0 5.0 7.0 20 Backfill Tamper 3.75 6.25 8.75 25

Nutsetters, to 3/8” 3.6 6.0 8.4 24 Compression Riveter 0.2 cu. ft. per cycle

Nutsetters, to 3/4” 4.5 7.5 10.5 30 Air Motor,

1 Horsepower 3.75 6.3 8.75 25

Impact Wrench, 1/4” 2.25 3.75 5.3 15 Air Motor,

2 Horsepower 7.5 12.5 17.5 50

Impact Wrench, 3/8” 3.0 5.0 7.0 20 Air Motor,

3 Horsepower 11.25 18.75 26.3 75
Impact Wrench, 5/8” 4.5 7.5 10.5 30
Paint Spray Gun
Impact Wrench, 3/4” 5.25 8.75 12.25 35 (Production) 3.0 5.00 7.00 20

Impact Wrench, 1” 6.75 11.25 15.75 45 ,HAMMERS

Impact Wrench, 1-1/4” 8.25 13.75 19.2 55 Scaling Hammer 1.3 3.0 4.2 12

Die Grinder, Small 2.25 3.75 5.3 15 Chipping Hammer 4.5 7.5 10.5 30
Die Grinder, Medium 3.6 6.0 8.4 24
Riveting Hammer,
Horizontal Grinder, 2” 3.0 5.0 7.0 20 Light 2.25 3.75 5.25 15

Horizontal Grinder, 4” 9.0 15.0 21.0 60 Riveting Hammer,

Heavy 4.5 7.5 10.5 30
Horizontal Grinder, 6” 9.0 15.0 21.0 60
SAWS

Circular, 8” 6.75 11.25 15.75 45

Horizontal Grinder, 8” 12.0 20.0 28.0 80
Circular, 12” 9.75 16.25 23.8 65
Vertical Grinders and
Sanders, 5” Pad 5.25 8.75 12.25 35 Chain, Lightweight 4.20 7.0 9.8 28
Vertical Grinders and
Sanders, 7” Pad 9.0 15.0 21.0 60 Chain, Heavy Duty 13.1 21.8 30.5 87

Vertical Grinders and

Sanders, 9” Pad 10.5 17.5 24.5 70

Burring Toll, Small 2.25 3.75 5.3 15

Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)

OM-282374 Page 91
 SECTION 16 − 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.
16-1. Selecting Equipment
1 Generator Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
1 Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
 Be sure equipment has double
insulated symbol and/or word-
ing on it.
! Do not use 2-prong plug un-
less equipment is double
insulated.

2 3

OR

gen_pwr 2018−06 − ST-800 577

16-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

800 652-D

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

OM-282374 Page 92
16-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #8 AWG or larger insulated
1 2 copper wire.
GND/PE 3 Ground Device
 Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
2 3 Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

ST-800 576-B

16-4. How Much Power Does Equipment Require?

1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires
approximately six times more power
while starting the motor than when
3 running (see Section 16-8).
VOLTS 115 3 Rating Data
2 AMPS 4.5
1 Hz 50/60 Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its
running power requirement in watts.
3 4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.

S-0623

OM-282374 Page 93
16-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

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

16-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10,500 2800
Farm Duty Motors Std. (e.g. Conveyors, Feed 1/3 HP 1720 720
Augers, Air Compressors) 1/2 HP 2575 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10,550 2850
3 HP 15,900 3900
5 HP 23,300 6800
Farm Duty Motors High Torque 1-1/2 HP 8100 2000
(e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, 5 HP 23,300 6000
Bunk Feeders)
7-1/2 HP 35,000 8000
10 HP 46,700 10,700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050
OM-282374 Page 94
16-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment Rating Starting Watts Running Watts
Hand Drill 1/4 in. 350 350
3/8 in. 400 400
1/2 in. 600 600
Circular Saw 6-1/2 in. 500 500
7-1/4 in. 900 900
8-1/4 in. 1400 1400
Table Saw 9 in. 4500 1500
10 in. 6300 1800
Band Saw 14 in. 2500 1100
Bench Grinder 6 in. 1720 720
8 in. 3900 1400
10 in. 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10,500 2800
Electric Chain Saw 1-1/2 HP, 12 in. 1100 1100
2 HP, 14 in. 1100 1100
Electric Trimmer Standard 9 in. 350 350
Heavy Duty 12 in. 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in. 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 GPH 600 200
Centrifugal Pump 900 GPH 900 500
Floor Polisher 3/4 HP, 16 in. 4500 1400
1 HP, 20 in. 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-282374 Page 95
16-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

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

1 Motor Start Code

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

S-0624

16-9. How Much Power Can Generator Supply?

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

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

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

OM-282374 Page 96
16-10. Typical Connections To Supply Standby Power

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.
! Properly install, ground, and
operate this equipment ac-
cording to its Owner’s
Manual and national, state,
and local codes.
! Do not connect to any elec-
1 2 3 4 trical distribution system
Fused normally supplied by utility
Utility Welding power unless a proper trans-
Disconnect
Electrical Transfer Switch Generator fer switch and grounding
Switch
Service Output procedure are employed.
(If Required)
 Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
5 ages.
1 Utility Electrical Service
Essential 2 Transfer Switch (Double-Throw)
Loads
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welder/Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 16-4).

OM-282374 Page 97
16-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

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

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

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

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

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

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

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

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

OM-282374 Page 98
 Effective January 1, 2018
(Equipment with a serial number preface of MJ or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective date of 6. 90 Days — Parts
1-800-4-A-MILLER this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
for your local the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, * Canvas Covers
Miller distributor. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND * Induction Heating Coils and Blankets, Cables, and
FITNESS. Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any * M-Guns
warranted parts or components that fail due to such defects in material * MIG Guns, Subarc (SAW) Torches, and External
Your distributor also gives or workmanship. Miller must be notified in writing within thirty (30) days Cladding Heads
you ... of such defect or failure, at which time Miller will provide instructions on * Remote Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted * Replacement Parts (No labor)
Service as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
You always get the fast, description of the fault and the troubleshooting steps taken to identify
reliable response you failed components and the cause of their failure. Miller’s True Blue® Limited Warranty shall not apply to:
need. Most replacement Miller shall honor warranty claims on warranted equipment listed below 1. Consumable components; such as contact tips,
parts can be in your in the event of such a failure within the warranty time periods. All cutting nozzles, contactors, brushes, relays, work
hands in 24 hours. warranty time periods start on the delivery date of the equipment to the station table tops and welding curtains, or parts that
original end-user purchaser, and not to exceed twelve months after the fail due to normal wear. (Exception: brushes and
Support equipment is shipped to a North American distributor or eighteen relays are covered on all engine-driven products.)
Need fast answers to the months after the equipment is shipped to an International distributor. 2. Items furnished by Miller, but manufactured by others,
tough welding questions? 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
Contact your distributor. * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
The expertise of the Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
distributor and Miller is 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
there to help you, every * Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
step of the way.
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL AND
* Plasma Arc Cutting Power Sources INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE
* Process Controllers AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders The exclusive remedies for warranty claims are, at Miller’s option,
* Transformer/Rectifier Power Sources either: (1) repair; or (2) replacement; or, if approved in writing by
3. 2 Years — Parts and Labor Miller, (3) the pre-approved cost of repair or replacement at an
* Auto-Darkening Helmet Lenses − Classic Series Only authorized Miller service station; or (4) payment of or credit for the
(No Labor) purchase price (less reasonable depreciation based upon use).
* Auto-Darkening Weld Masks (No Labor) Products may not be returned without Miller’s written approval.
* Fume Extractors − Capture 5, Filtair 400 and Industrial Return shipment shall be at customer’s risk and expense.
Collector Series The above remedies are F.O.B. Appleton, WI, or Miller’s authorized
4. 1 Year — Parts and Labor Unless Specified service facility. Transportation and freight are the customer’s
* AugmentedArc and LiveArc Welding Systems responsibility. TO THE EXTENT PERMITTED BY LAW, THE
* Automatic Motion Devices REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO
* Bernard BTB Air-Cooled MIG Guns (No Labor) EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT,
* CoolBelt and CoolBand Blower Unit (No Labor) SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
* Desiccant Air Dryer System (INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL
* External Monitoring Equipment and Sensors THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY
* Field Options IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION,
(NOTE: Field options are covered for the remaining INCLUDING ANY IMPLIED WARRANTY OF
warranty period of the product they are installed in, MERCHANTABILITY OR FITNESS FOR PARTICULAR
or for a minimum of one year — whichever is PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.
greater.) Some US states do not allow limiting the duration of an implied
* RFCS Foot Controls (Except RFCS-RJ45) warranty or the exclusion of certain damages, so the above
* Fume Extractors − Filtair 130, MWX and SWX Series limitations may not apply to you. This warranty provides specific
* HF Units legal rights, and other rights may be available depending on your
state. In Canada, some provinces provide additional warranties or
* ICE/XT Plasma Cutting Torches (No Labor)
remedies, and to the extent the law prohibits their waiver, the
* Induction Heating Power Sources, Coolers limitations set out above may not apply. This Limited Warranty
(NOTE: Digital Recorders are Warranted provides specific legal rights, and other rights may be available, but
Separately by the Manufacturer.) may vary by province.
* 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)

miller_warr 2018-01
 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
Miller Electric Mfg. LLC
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

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

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2018 Miller Electric Mfg. LLC 2018−01