OM-247 432P

2013−08

Processes
TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue 400 Eco Pro CC/CV

®

File: Engine Drive

Visit our website at

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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

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

Mil_Thank 2009−09
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 11
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-7. CC (Stick/TIG) Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-8. CV (MIG/FCAW) Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-6. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Operating Optional Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 TABLE OF CONTENTS

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-5. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-9. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-10. Voltmeter/Ammeter Help Displays (Models With Optional Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2011−10

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

 Always verify the supply ground — check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information  When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-7. Read and tor first − double-check connections.
follow all Safety Standards.  Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and  Frequently inspect input power cord for damage or bare wiring —
repair this unit. replace cord immediately if damaged — bare wiring can kill.
 Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.  Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
ELECTRIC SHOCK can kill.  If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks or  Do not touch electrode if you are in contact with the work, ground,
severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input  Use only well-maintained equipment. Repair or replace damaged
power circuit and machine internal circuits are also live parts at once. Maintain unit according to manual.
when power is on. In semiautomatic or automatic wire
 Do not touch electrode holders connected to two welding ma-
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically chines at the same time since double open-circuit voltage will be
live. Incorrectly installed or improperly grounded present.
equipment is a hazard.  Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Do not touch live electrical parts.  Clamp work cable with good metal-to-metal contact to workpiece
 Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
 Insulate work clamp when not connected to workpiece to prevent
 Insulate yourself from work and ground using dry insulating mats contact with any metal object.
or covers big enough to prevent any physical contact with the work  Do not connect more than one electrode or work cable to any
or ground. single weld output terminal. Disconnect cable for process not in
 Do not use AC output in damp areas, if movement is confined, or if use.
there is a danger of falling. SIGNIFICANT DC VOLTAGE exists in inverter power
 Use AC output ONLY if required for the welding process. sources AFTER stopping engine.
 If AC output is required, use remote output control if present on  Stop engine on inverter and discharge input capacitors according
unit. to instructions in Maintenance Section before touching any parts.

 Additional safety precautions are required when any of the follow- HOT PARTS can burn.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such  Do not touch hot parts bare handed.
as floors, gratings, or scaffolds; when in cramped positions such
 Allow cooling period before working on equip-
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
ment.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a  To handle hot parts, use proper tools and/or wear heavy, insu-
semiautomatic DC constant voltage (wire) welder, 2) a DC manual lated welding gloves and clothing to prevent burns.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder FLYING METAL or DIRT can injure eyes.
is recommended. And, do not work alone!
 Disconnect input power or stop engine before installing or  Welding, chipping, wire brushing, and grinding
servicing this equipment. Lockout/tagout input power according to cause sparks and flying metal. As welds cool,
OSHA 29 CFR 1910.147 (see Safety Standards). they can throw off slag.
 Properly install, ground, and operate this equipment according to  Wear approved safety glasses with side shields even under your
its Owner’s Manual and national, state, and local codes. welding helmet.

OM-247 432 Page 1

  Do not weld on containers that have held combustibles, or on
FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Welding produces fumes and gases. Breathing these Safety Standards).
fumes and gases can be hazardous to your health.  Do not weld where the atmosphere may contain flammable dust,
 Keep your head out of the fumes. Do not breathe the fumes. gas, or liquid vapors (such as gasoline).
 If inside, ventilate the area and/or use local forced ventilation at the  Connect work cable to the work as close to the welding area as
arc to remove welding fumes and gases. practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire haz-
 If ventilation is poor, wear an approved air-supplied respirator. ards.
 Read and understand the Material Safety Data Sheets (MSDSs)
 Do not use welder to thaw frozen pipes.
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.  Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
 Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-  Wear oil-free protective garments such as leather gloves, heavy
person nearby. Welding fumes and gases can displace air and shirt, cuffless trousers, high shoes, and a cap.
lower the oxygen level causing injury or death. Be sure the breath-  Remove any combustibles, such as a butane lighter or matches,
ing air is safe. from your person before doing any welding.
 Do not weld in locations near degreasing, cleaning, or spraying op-  After completion of work, inspect area to ensure it is free of sparks,
erations. The heat and rays of the arc can react with vapors to form glowing embers, and flames.
highly toxic and irritating gases.
 Use only correct fuses or circuit breakers. Do not oversize or by-
 Do not weld on coated metals, such as galvanized, lead, or pass them.
cadmium plated steel, unless the coating is removed from the weld
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
area, the area is well ventilated, and while wearing an air-supplied
for hot work and have a fire watcher and extinguisher nearby.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
 Shut off compressed gas supply when not in use.
 Always ventilate confined spaces or use ap-  Wear approved ear protection if noise level is
proved air-supplied respirator. high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
ARC RAYS can burn eyes and skin. can affect Implanted Medical Devices.

Arc rays from the welding process produce intense  Wearers of Pacemakers and other Implanted
visible and invisible (ultraviolet and infrared) rays that Medical Devices should keep away.
can burn eyes and skin. Sparks fly off from the weld.  Implanted Medical Device wearers should consult their doctor
 Wear an approved welding helmet fitted with a proper shade of filter and the device manufacturer before going near arc welding, spot
lenses to protect your face and eyes from arc rays and sparks welding, gouging, plasma arc cutting, or induction heating
when welding or watching (see ANSI Z49.1 and Z87.1 listed in operations.
Safety Standards).
CYLINDERS can explode if damaged.
 Wear approved safety glasses with side shields under your
helmet.
Compressed gas cylinders contain gas under high
 Use protective screens or barriers to protect others from flash, pressure. If damaged, a cylinder can explode. Since
glare, and sparks; warn others not to watch the arc. gas cylinders are normally part of the welding process,
 Wear protective clothing made from durable, flame-resistant mate- be sure to treat them carefully.
rial (leather, heavy cotton, or wool) and foot protection.  Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
WELDING can cause fire or explosion.  Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Welding on closed containers, such as tanks, drums,  Keep cylinders away from any welding or other electrical circuits.
or pipes, can cause them to blow up. Sparks can fly off  Never drape a welding torch over a gas cylinder.
from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of  Never allow a welding electrode to touch any cylinder.
electrode to metal objects can cause sparks, explosion, overheating,  Never weld on a pressurized cylinder — explosion will result.
or fire. Check and be sure the area is safe before doing any welding.  Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
and associated parts in good condition.
this is not possible, tightly cover them with approved covers.
 Turn face away from valve outlet when opening cylinder valve.
 Do not weld where flying sparks can strike flammable material.
 Keep protective cap in place over valve except when cylinder is in
 Protect yourself and others from flying sparks and hot metal.
use or connected for use.
 Be alert that welding sparks and hot materials from welding can  Use the right equipment, correct procedures, and sufficient num-
easily go through small cracks and openings to adjacent areas. ber of persons to lift and move cylinders.
 Watch for fire, and keep a fire extinguisher nearby.  Read and follow instructions on compressed gas cylinders,
 Be aware that welding on a ceiling, floor, bulkhead, or partition can associated equipment, and Compressed Gas Association (CGA)
cause fire on the hidden side. publication P-1 listed in Safety Standards.

OM-247 432 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. HOT PARTS can burn.
 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles un-  Do not touch hot parts bare handed.
less the unit has a battery charging feature designed for this pur-  Allow cooling period before working on equip-
pose. ment.
 Observe correct polarity (+ and −) on batteries.  To handle hot parts, use proper tools and/or
 Disconnect negative (−) cable first and connect it last. wear heavy, insulated welding gloves and
clothing to prevent burns.
 Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged. STEAM AND HOT COOLANT can burn.
 Follow battery manufacturer’s instructions when working on or
 If possible, check coolant level when engine is
near a battery.
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
 Stop engine and let it cool off before checking or manual).
adding fuel.  If the engine is warm, checking is needed, and there is no over-
 Do not add fuel while smoking or if unit is near flow tank, follow the next two statements.
any sparks or open flames.  Wear safety glasses and gloves and put a rag over radiator cap.
 Do not overfill tank — allow room for fuel to expand.  Turn cap slightly and let pressure escape slowly before
 Do not spill fuel. If fuel is spilled, clean up before starting engine. completely removing cap.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.
Using a generator indoors CAN KILL
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.
 Keep all doors, panels, covers, and guards
closed and securely in place.  Only use OUTSIDE and far away from windows, doors, and
vents.
 Stop engine before installing or connecting unit.
 Have only qualified persons remove doors, panels, covers, or BATTERY ACID can BURN SKIN and EYES.
guards for maintenance and troubleshooting as necessary.
 To prevent accidental starting during servicing, disconnect  Do not tip battery.
negative (−) battery cable from battery.  Replace damaged battery.
 Keep hands, hair, loose clothing, and tools away from moving  Flush eyes and skin immediately with water.
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
any equipment in the compressed air system. Design compressed  Do not work under or around any equipment that is supported only
air system so failure of any component will not put people or prop- by air pressure. Properly support equipment by mechanical
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-247 432 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, turn off and lockout/
 Before working on compressed air system,
tagout unit, release pressure, and be sure air pressure cannot be
turn off and lockout/tagout unit, release pres-
accidentally applied.
sure, and be sure air pressure cannot be acci-
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.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and HOT PARTS can burn.
a cap when working on compressed air system.
 Do not touch hot compressor or air system
 Use soapy water or an ultrasonic detector to search for parts.
leaks−−never use bare hands. Do not use equipment if leaks are
 Allow cooling period before working on equip-
found.
ment.
 Reinstall doors, panels, covers, or guards when servicing is
 To handle hot parts, use proper tools and/or wear heavy, insu-
finished and before starting unit.
lated welding gloves and clothing to prevent burns.
 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.
 Do not use compressed air for breathing.  Read and follow all labels and the Owner’s
 Use only for cutting, gouging, and tools. Manual carefully before installing, operating, or
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.
 Release air pressure from tools and system be-  Perform maintenance and service according to the Owner’s
fore servicing, adding or changing attach- Manuals, industry standards, and national, state, and local
ments, or opening compressor oil drain or oil fill codes.
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.  Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
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 equipment of adequate capacity to lift and proper guards in a safe location wearing proper
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-247 432 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.
 Use proper static-proof bags and boxes to
 Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.
clothing when working on a battery.
 Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery. TILTING OF TRAILER can injure.
 Do not allow tools to cause sparks when working on a battery.  Use tongue jack or blocks to support weight.
 Do not use welder to charge batteries or jump start vehicles un-  Properly install welding generator onto trailer
less it has a battery charging feature designed for this purpose. according to instructions supplied with trailer.
 Observe correct polarity (+ and −) on batteries.
 Disconnect negative (−) cable first and connect it last.
 Keep sparks, flames, cigarettes, and other ignition sources READ INSTRUCTIONS.
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.  Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
 Follow battery manufacturer’s instructions when working on or servicing unit. Read the safety information at
near a battery. the beginning of the manual and in each
 Have only qualified persons do battery charging work. section.
 If battery is being removed from a vehicle for charging, discon-  Use only genuine replacement parts from the manufacturer.
nect negative (−) cable first and connect it last. To prevent an arc,  Perform maintenance and service according to the Owner’s
make sure all accessories are off. Manuals, industry standards, and national, state, and local
 Charge lead-acid batteries only. Do not use battery charger to codes.
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries. H.F. RADIATION can cause interference.
 Do not charge a frozen battery.
 High-frequency (H.F.) can interfere with radio
 Do not use damaged charging cables.
navigation, safety services, computers, and
 Do not charge batteries in a closed area or where ventilation is communications equipment.
restricted.
 Have only qualified persons familiar with
 Do not charge a battery that has loose terminals or one showing electronic equipment perform this installation.
damage such as a cracked case or cover.
 The user is responsible for having a qualified electrician
 Before charging battery, select correct charger voltage to match promptly correct any interference problem resulting from the
battery voltage. installation.
 Set battery charging controls to the Off position before connect-  If notified by the FCC about interference, stop using the
ing to battery. Do not allow battery charging clips to touch each equipment at once.
other.
 Have the installation regularly checked and maintained.
 Keep charging cables away from vehicle hood, door, or moving
 Keep high-frequency source doors and panels tightly shut, keep
parts.
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

WELDING WIRE can injure.  Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
 Do not press gun trigger until instructed to do processors, computers, and computer-driven
so. equipment such as robots.
 Do not point gun toward any part of the body,  Be sure all equipment in the welding area is
other people, or any metal when threading electromagnetically compatible.
welding wire.  To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive elec-
OVERUSE can cause OVERHEATING. tronic equipment.
 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,
 Do not block or filter airflow to unit. using line filters, or shielding the work area.

OM-247 432 Page 5

1-6. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
is available as a free download from the American Welding Society at www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
www.osha.gov).
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
website:www.cganet.com). mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/port-
W117.2, from Canadian Standards Association, Standards Sales, 5060 gen.pdf).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cdc.gov/NIOSH).

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). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, restrict access for passers−by or conduct individual risk as-
sessment for welders. All welders should use the following procedures 6. Do not work next to, sit or lean on the welding power source.
in order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
1. Keep cables close together by twisting or taping them, or using a feeder.
cable cover. About Implanted Medical Devices:
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-247 432 Page 6

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2011−10

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
NOTE − 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

à souder manuel (électrode enrobée) DC, 3) un poste à souder
Les symboles présentés ci-après sont utilisés tout au long du manuel AC avec tension à vide réduite. Dans la plupart des cas, un
présent manuel pour attirer votre attention et identifier les ris- poste courant continu de type CV est recommandé. Et, ne pas tra-
ques de danger. Lorsque vous voyez un symbole, soyez vailler seul!
vigilant et suivez les directives mentionnées afin d’éviter tout
 Couper l’alimentation ou arrêter le moteur avant de procéder à
danger. Les consignes de sécurité présentées ci-après ne
l’installation, à la réparation ou à l’entretien de l’appareil.
font que résumer l’information contenue dans les normes de
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
sécurité énumérées à la section 1-7. Veuillez lire et respecter
1910.147 (voir normes de sécurité).
toutes ces normes de sécurité.
 Installez, mettez à la terre et utilisez correctement cet équipement
L’installation, l’utilisation, l’entretien et les réparations ne conformément à son Manuel d’Utilisation et aux réglementations
doivent être confiés qu’à des personnes qualifiées. nationales, gouvernementales et locales.
 Installer et mettre à la terre correctement cet appareil conformé-
Au cours de l’utilisation, tenir toute personne à l’écart et plus ment à son manuel d’utilisation et aux codes nationaux,
particulièrement les enfants. provinciaux et municipaux.
 Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
UN CHOC ÉLECTRIQUE peut tuer. raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
Un simple contact avec des pièces électriques peut  En effectuant les raccordements d’entrée fixer d’abord le conduc-
provoquer une électrocution ou des blessures gra- teur de mise à la terre approprié et contre-vérifier les connexions.
ves. L’électrode et le circuit de soudage sont sous  Les câbles doivent être exempts d’humidité, d’huile et de graisse;
tension dès que l’appareil est sur ON. Le circuit protégez−les contre les étincelles et les pièces métalliques chau-
d’entrée et les circuits internes de l’appareil sont des.
également sous tension à ce moment-là. En soudage  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
semi-automatique ou automatique, le fil, le dévidoir, le pas endommagé ou dénudé − remplacer le cordon immédiatement
logement des galets d’entraînement et les pièces s’il est endommagé − un câble dénudé peut provoquer une électro-
métalliques en contact avec le fil de soudage sont cution.
sous tension. Des matériels mal installés ou mal mis  Mettre l’appareil hors tension quand on ne l’utilise pas.
à la terre présentent un danger.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
 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 se servir de source électrique à courant électrique dans les  Ne pas toucher des porte électrodes connectés à deux machines
zones humides, dans les endroits confinés ou là où on risque de en même temps à cause de la présence d’une tension à vide dou-
tomber. blée.
 Se servir d’une source électrique à courant électrique UNIQUE-  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
MENT si le procédé de soudage le demande. sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
 Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil  Porter un harnais de sécurité quand on travaille en hauteur.
en est équipé.  Maintenir solidement en place tous les panneaux et capots.
 Fixer le câble de retour de façon à obtenir un bon contact métal-
 Des précautions de sécurité supplémentaires sont requises dans
métal avec la pièce à souder ou la table de travail, le plus près pos-
des environnements à risque comme: les endroits humides ou
sible de la soudure.
lorsque l’on porte des vêtements mouillés; sur des structures mé-
talliques au sol, grillages et échafaudages; dans des positions  Isoler la pince de masse quand pas mis à la pièce pour éviter le
assises, à genoux et allongées; ou quand il y a un risque important contact avec tout objet métallique.
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser  Ne pas raccorder plus d’une électrode ou plus d’un câble de
les appareils suivants dans l’ordre de préférence: 1) un poste à masse à une même borne de sortie de soudage. Débrancher le
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste câble pour le procédé non utilisé.
OM-247 432 Page 7
 Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
 Couper l’alimentation du poste et décharger les condensateurs yeux et sur la peau.
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants. Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
LES PIÈCES CHAUDES peuvent (ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
provoquer des brûlures.
soudage.
 Ne pas toucher à mains nues les parties chau-  Porter un casque de soudage approuvé muni de verres filtrants
des. approprié pour protéger visage et yeux pour protéger votre visage
 Prévoir une période de refroidissement avant et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
de travailler à l’équipement. et Z87.1 énuméré dans les normes de sécurité).
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  Porter des lunettes de sécurité avec écrans latéraux même sous
dés et porter des gants de soudage et des vêtements épais pour votre casque.
éviter les brûlures.  Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
 Porter des vêtements confectionnés avec des matières résistan-
DES PIECES DE METAL ou DES tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
SALETES peuvent provoquer protection.
des blessures dans les yeux. LE SOUDAGE peut provoquer un
incendie ou une explosion.
 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 Le soudage effectué sur des conteneurs fermés tels
métalliques volantes. Pendant la période de refroidissement des que des réservoirs, tambours ou des conduites peut
soudures, elles risquent de projeter du laitier. provoquer leur éclatement. Des étincelles peuvent
 Porter des lunettes de sécurité avec écrans latéraux ou un écran être projetées de l’arc de soudure. La projection d’étincelles, des
facial. pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
LES FUMÉES ET LES GAZ peu- vérifier et s’assurer que l’endroit ne présente pas de danger.
vent être dangereux.
 Déplacer toutes les substances inflammables à une distance de
Le soudage génère des fumées et des gaz. Leur 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
inhalation peut être dangereux pour votre santé. soigneusement avec des protections homologués.
 Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 Se protéger et d’autres personnes de la projection d’étincelles et
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au de métal chaud.
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs
fissures et des ouvertures.
approuvé.
 Surveiller tout déclenchement d’incendie et tenir un extincteur à
 Lire et comprendre les spécifications de sécurité des matériaux proximité.
(MSDS) et les instructions du fabricant concernant les métaux, les  Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou  Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu ils n aient
un surveillant dûment formé de se tenir à proximité. Des fumées et été préparés correctement conformément à AWS F4.1 et AWS
des gaz de soudage peuvent déplacer l’air et abaisser le niveau A6.0 (voir les Normes de Sécurité).
d’oxygène provoquant des blessures ou des accidents mortels.  Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
S’assurer que l’air de respiration ne présente aucun danger. peurs inflammables (vapeur d’essence, par exemple).
 Ne pas souder dans des endroits situés à proximité d’opérations  Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for- longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants. quant des risques d’électrocution, d’étincelles et d’incendie.
 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier lées.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
 En cas de non utilisation, enlever la baguette d’électrode du porte-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
électrode ou couper le fil à la pointe de contact.
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent  Porter des vêtements de protection dépourvus d’huile tels que des
dégager des fumées toxiques en cas de soudage. gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
LES ACCUMULATIONS DE GAZ  Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
risquent de provoquer des blessures
ou même la mort.  Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
ce d’étincelles incandescentes ni de flammes.
 Fermer l’alimentation du gaz comprimé en cas  Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
de non utilisation. Ne pas augmenter leur puissance; ne pas les ponter.
 Veiller toujours à bien aérer les espaces confinés ou se servir  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
d’un respirateur d’adduction d’air homologué. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
OM-247 432 Page 8
  Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Le bruit des processus et des équipements peut
affecter l’ouïe.  Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
 Porter des protections approuvés pour les de se renverser.
oreilles si le niveau sonore est trop élevé.  Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants mé-  Ne jamais placer une torche de soudage sur une bouteille à gaz.
dicaux.  Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
 Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à  Ne jamais souder une bouteille pressurisée − risque d’explosion.
distance.
 Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
 Les porteurs d’implants médicaux doivent consulter leur tuyaux et raccords convenables pour cette application spécifique;
médecin et le fabricant du dispositif avant de s’approcher de la les maintenir ainsi que les éléments associés en bon état.
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage  Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
par induction. bouteille.
 Maintenir le chapeau de protection sur la soupape, sauf en cas
Si des BOUTEILLES sont endomma- d’utilisation ou de branchement de la bouteille.
gées, elles pourront exploser.
 Utiliser les équipements corrects, les bonnes procédures et suffi-
Des bouteilles de gaz comprimé protecteur contien- samment de personnes pour soulever et déplacer les bouteilles.
nent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les bouteilles de gaz font  Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
normalement partie du procédé de soudage, les manipuler avec
Gas Association) mentionné dans les principales normes de sécu-
précaution.
rité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE Les PIÈCES MOBILES peuvent causer

peut provoquer des blessures. des blessures.
 Toujours porter une protection faciale, des  S’abstenir de toucher des parties mobiles telles
gants en caoutchouc et vêtements de protec- que des ventilateurs, courroies et rotors.
tion lors d’une intervention sur la batterie.
 Maintenir fermés et verrouillés les portes, panneaux,
 Arrêter le moteur avant de débrancher ou de brancher des câbles recouvrements et dispositifs de protection.
de batterie, des câbles de chargeur de batterie (le cas échéant) ou  Arrêter le moteur avant d’installer ou brancher l’appareil.
de batterie d’entretien.
 Lorsque cela est nécessaire pour des travaux d entretien et de
 Eviter de provoquer des étincelles avec les outils en travaillant sur dépannage, faire retirer les portes, panneaux, recouvrements ou
la batterie. dispositifs de protection uniquement par du personnel qualifié.
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou  Pour empêcher tout démarrage accidentel pendant les travaux
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf d’entretien, débrancher le câble négatif (−) de batterie de la borne.
si l’appareil dispose d’une fonctionnalité de charge de batterie  Ne pas approcher les mains, cheveux, vêtements lâches et outils
destinée à cet usage. des organes mobiles.
 Observer la polarité correcte (+ et −) sur les batteries.  Remettre en place les portes, panneaux, recouvrements ou
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dispositifs de protection à la fin des travaux d’entretien et avant de
dernier lieu. mettre le moteur en marche.
 Les sources d’étincelles, flammes nues, cigarettes et autres  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
sources d’inflammation doivent être maintenues à l’écart des mise en route accidentelle du moteur.
batteries. Ces dernières produisent des gaz explosifs en  Bloquer le volant moteur pour éviter sa rotation lors d’une
fonctionnement normal et en cours de charge. intervention sur le générateur.
 Respecter les consignes du fabricant de la batterie pour LES ÉTINCELLES À L’ÉCHAPPEMENT
travailler sur une batterie ou à proximité. peuvent provoquer un incendie.
LE CARBURANT MOTEUR peut pro-  Empêcher les étincelles d’échappement du
voquer un incendie ou une explosion. moteur de provoquer un incendie.
 Utiliser uniquement un pare-étincelles
 Arrêter le moteur avant de vérifier le niveau de approuvé − voir codes en vigueur.
carburant ou de faire le plein.
 Ne pas faire le plein en fumant ou proche d’une source d’étincel- LES PIÈCES CHAUDES peuvent
les ou d’une flamme nue. provoquer des brûlures.
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.  Ne pas toucher des parties chaudes à mains
nues.
 Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.  Prévoir une période de refroidissement avant de
travailler à l’équipement.
 Jeter les chiffons dans un récipient ignifuge.
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
 Toujours garder le pistolet en contact avec le réservoir lors du dés et porter des gants de soudage et des vêtements épais pour
remplissage. éviter les brûlures.

OM-247 432 Page 9

 LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro-
REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et
provoquer des brûlures. sur la PEAU.
 Il est préférable de vérifier le liquide de refroi-  Ne pas renverser la batterie.
dissement une fois le moteur refroidi pour éviter  Remplacer une batterie endommagée.
de se brûler.
 Rincer immédiatement les yeux et la peau à l’eau.
 Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré- LA CHALEUR DU MOTEUR peut pro-
cisé autrement dans la section maintenance du manuel du voquer un incendie.
moteur).
 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-  Ne pas placer l’appareil sur, au-dessus ou à
me suivant. proximité de surfaces inflammables.
 Mettre des lunettes de sécurité et des gants, placer un torchon sur  Tenir à distance les produits inflammables de l’échappement.
le bouchon du radiateur.
 Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
 Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
ble et inodore.
 JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.

2-4. Dangers liés à l’air comprimé

Un ÉQUIPEMENT PNEUMATIQUE risque MÉTAL CHAUD provenant du décou-
de provoquer des blessures ou même page ou du gougeage à l’arc risque de
la mort. provoquer un incendie ou une explo-
sion.
 Une installation ou une utilisation incorrecte de
cet appareil pourrait conduire à des dégâts
 Ne pas découper ou gouger à proximité de
matériels ou corporels. Seul un personnel
produits inflammables.
qualifié est autorisé à installer, utiliser et
entretenir cet appareil conformément à son  Attention aux risques d’incendie: tenir un extincteur à proximité.
manuel d’utilisation, aux normes industrielles et
aux codes nationaux, d’état ou locaux.
 Ne pas dépasser le débit nominal ou la capacité du compresseur L’AIR COMPRIMÉ risque de provoquer
ou de tout équipement du circuit d’air comprimé. Concevoir des blessures ou même la mort.
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident  Avant d’intervenir sur le circuit d’air comprimé,
matériel ou corporel. couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
 Avant d’intervenir sur le circuit d’air comprimé, couper
et s’assurer que le circuit d’air ne peut être mis
l’alimentation électrique, verrouiller et étiqueter l’appareil,
sous pression par inadvertance.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.  Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
 Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant  Avant d’utiliser l’appareil, contrôler
les consignes du fabricant. les composants du circuit d’air comprimé,
les branchements et les flexibles en
 Ne pas modifier ou altérer le compresseur ou les équipements recherchant tout signe de détérioration, de fuite
fournis par le fabricant. Ne pas débrancher, désactiver ou et d’usure.
neutraliser les équipements de sécurité du circuit d’air
comprimé.  Ne pas diriger un jet d’air vers soi−même ou vers autrui.
 Utiliser uniquement des composants et accessoires  Pour intervenir sur un circuit d’air comprimé, porter un équipement
homologués par le fabricant. de protection tel que des lunettes de sécurité, des gants de cuir,
 Se tenir à l’écart de tout point présentant un danger de pincement une chemise et un pantalon en tissu résistant, des chaussures
ou d’écrasement créé par l’équipement raccordé au circuit d’air montantes et une coiffe.
comprimé.  Pour rechercher des fuites, utiliser de l’eau savonneuse ou
 Ne pas intervenir sous ou autour d’un équipement qui n’est un détecteur à ultrasons, jamais les mains nues. En cas
soutenu que par la pression pneumatique. Soutenir l’équipement de détection de fuite, ne pas utiliser l’équipement.
de façon appropriée par un moyen mécanique.
 Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
 En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
OM-247 432 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
 Demander seulement à un personnel qualifié d’enlever
la mort.
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
 Ne pas inhaler d’air comprimé.
 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
des accessoires et avant d’ouvrir le bouchon avant d’intervenir sur l’équipement.
de vidange ou de remplissage d’huile
 Ne pas toucher aux pièces chaudes, utiliser les outils
du compresseur.
recommandés 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
 Maintenir fermés et verrouillés les portes, l’installation, l’utilisation ou l’entretien de
panneaux, recouvrements et dispositifs l’appareil. Lire les informations de sécurité au
de protection. début du manuel et dans chaque section.
 Ne pas approcher les mains, cheveux, vêtements lâches et outils  N’utiliser que les pièces de rechange recommandées par le
des organes mobiles. constructeur.
 Avant d’intervenir sur le circuit d’air comprimé, couper  Effectuer l’entretien en respectant les manuels d’utilisation,
l’alimentation électrique, verrouiller et étiqueter l’appareil, les normes industrielles et les codes nationaux, d’état et locaux.

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-  Ne pas laisser tourner le moteur trop lentement sous risque d’en-
duits inflammables. 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  Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
mettre l’appareil en service. s’il y a lieu.

LA CHUTE DE L’ÉQUIPEMENT LES ÉTINCELLES PROJETÉES

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-
 Utiliser un équipement de levage de capacité suffisante pour que l’on porte l’équipement homologué de pro-
lever l’appareil. tection du visage, des mains et du corps.
 En utilisant des fourches de levage pour déplacer l’unité, s’assu-  Les étincelles risquent de causer un incendie − éloigner toute
rer que les fourches sont suffisamment longues pour dépasser substance inflammable.
du côté opposé de l’appareil.
 Tenir l’équipement (câbles et cordons) à distance des véhicules Les PIÈCES MOBILES peuvent
mobiles lors de toute opération en hauteur. causer des blessures.
 Suivre les consignes du Manuel des applications pour l’équation  Ne pas s’approcher des organes mobiles.
de levage NIOSH révisée (Publication Nº94−110) lors du levage  Ne pas s’approcher des points de coincement
manuelle de pièces ou équipements lourds. tels que des rouleaux de commande.

OM-247 432 Page 11

 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI-
SION DE LA BATTERIE peuvent QUES peuvent endommager les
provoquer des blessures. circuits imprimés.
La recharge de batterie n’existe pas sur tous les  Établir la connexion avec la barrette de terre
modèles. avant de manipuler des cartes ou des pièces.
 Utiliser des pochettes et des boîtes antistatiques pour stocker,
 Toujours porter une protection faciale, des gants en caoutchouc déplacer ou expédier des cartes de circuits imprimes.
et vêtements de protection lors d’une intervention sur la batterie.
 Arrêter le moteur avant de débrancher ou de brancher des UNE REMORQUE QUI BASCULE peut
câbles de batterie, des câbles de chargeur de batterie (le cas provoquer des blessures.
échéant) ou de batterie d’entretien.  Utiliser les supports de la remorque ou des
 Eviter de provoquer des étincelles avec les outils en travaillant blocs pour soutenir le poids.
sur la batterie.  Installer convenablement le poste sur la remor-
 Ne pas utiliser l’appareil de soudage pour charger des batteries que comme indiqué dans le manuel s’y rappor-
ou faire démarrer des véhicules à l’aide de câbles de démarrage, tant.
sauf si l’appareil dispose d’une fonctionnalité de charge de
batterie destinée à cet usage. LIRE LES INSTRUCTIONS.
 Observer la polarité correcte (+ et −) sur les batteries.
 Lire et appliquer les instructions sur les
 Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
étiquettes et le Mode d’emploi avant
dernier lieu.
l’installation, l’utilisation ou l’entretien de
 Les sources d’étincelles, flammes nues, cigarettes et autres l’appareil. Lire les informations de sécurité au
sources d’inflammation doivent être maintenues à l’écart des début du manuel et dans chaque section.
batteries. Ces dernières produisent des gaz explosifs en
 N’utiliser que les pièces de rechange recommandées par le
fonctionnement normal et en cours de charge.
constructeur.
 Respecter les consignes du fabricant de la batterie pour
 Effectuer l’entretien en respectant les manuels d’utilisation,
travailler sur une batterie ou à proximité.
les normes industrielles et les codes nationaux, d’état et locaux.
 Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
LE RAYONNEMENT HAUTE FRÉ-
 Pour enlever la batterie d’un véhicule pour la recharge, QUENCE (H.F.) risque de provoquer
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les
des interférences.
accessoires sont débranchés.  Le rayonnement haute fréquence (H.F.) peut
 Ne charger que des batteries plomb−acide. Ne pas utiliser le provoquer des interférences avec les équipe-
chargeur de batterie pour alimenter un autre circuit électrique ments de radio−navigation et de communica-
basse tension ou pour charger des batteries sèches. tion, les services de sécurité et les ordinateurs.
 Ne pas charger une batterie gelée.  Demander seulement à des personnes qualifiées familiarisées
 Ne pas utiliser de câbles de charge endommagés. avec des équipements électroniques de faire fonctionner l’installa-
 Ne pas charger des batteries dans un espace fermé ou en tion.
l’absence d’une ventilation.  L’utilisateur est tenu de faire corriger rapidement par un électricien
 Ne pas charger une batterie dont les bornes sont desserrées ou qualifié les interférences résultant de l’installation.
présentant une détérioration comme par exemple un boîtier ou  Si le FCC signale des interférences, arrêter immédiatement l’ap-
un couvercle fissuré. pareil.
 Avant de charger une batterie, sélectionner la tension de charge  Effectuer régulièrement le contrôle et l’entretien de l’installation.
correspondant à la tension de la batterie.  Maintenir soigneusement fermés les portes et les panneaux des
 Régler les commandes de charge de batterie sur la position sources de haute fréquence, maintenir les éclateurs à une distan-
d’arrêt avant de brancher la batterie. Veiller à ce que les pinces ce correcte et utiliser une terre et un blindage pour réduire les
de charge ne se touchent pas. interférences éventuelles.
 Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
 L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et
LES FILS DE SOUDAGE peuvent l’équipement commandé par ordinateur tel que
provoquer des blessures. les robots.
 Ne pas appuyer sur la gâchette avant d’en  Veiller à ce que tout l’équipement de la zone de soudage soit
avoir reçu l’instruction. compatible électromagnétiquement.
 Ne pas diriger le pistolet vers soi, d’autres per-  Pour réduire la possibilité d’interférence, maintenir les câbles de
sonnes ou toute pièce mécanique en enga- soudage aussi courts que possible, les grouper, et les poser
geant le fil de soudage. aussi bas que possible (ex. par terre).
 Veiller à souder à une distance de 100 mètres de tout équipe-
L’EMPLOI EXCESSIF peut ment électronique sensible.
SURCHAUFFER L’ÉQUIPEMENT.  Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
 Laisser l’équipement refroidir ; respecter le fac-
 En cas d’interférences après avoir pris les mesures précéden-
teur de marche nominal.
tes, il incombe à l’utilisateur de prendre des mesures supplé-
 Réduire le courant ou le facteur de marche mentaires telles que le déplacement du poste, l’utilisation de câ-
avant de poursuivre le soudage. bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
 Ne pas obstruer les passages d’air du poste. teurs dans la zone de travail.

OM-247 432 Page 12

2-6. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
Les gaz d’échappement des moteurs contiennent des pro-
dont l’État de Californie reconnaît qu’ils provoquent des mal-
duits chimiques dont l’État de Californie reconnaît qu’ils
formations congénitales et, dans certains cas, des cancers.
provoquent des cancers et des malformations congénitales
(Code de santé et de sécurité de Californie, chapitre 25249.5
ou autres problèmes de procréation.
et suivants)
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi- Les gaz d’échappement des moteurs diesel et certains de
ques dont l’État de Californie reconnaît qu’ils provoquent des leurs composants sont reconnus par l’État de Californie com-
cancers et des malformations congénitales ou autres me provoquant des cancers et des malformations
problèmes de procréation. Se laver les mains après manipu- congénitales ou autres problèmes de procréation.
lation.

Ce produit contient des produits chimiques, notamment du

plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
is available as a free download from the American Welding Society at www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
www.osha.gov).
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
website:www.cganet.com). mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/port-
W117.2, from Canadian Standards Association, Standards Sales, 5060 gen.pdf).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cdc.gov/NIOSH).

2-8. Informations relatives aux CEM

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

OM-247 432 Page 13

 SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

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

Read Owner’s Manual. Follow instructions to activate battery.

Safe48 2012−05

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 2012−05

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

Do not use ether. Using ether voids warranty. See engine Owner’s Manual.

Safe89 2012−07

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2012−07

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

Safe91 2012−07

OM-247 432 Page 14

3-2. Miscellaneous Symbols And Definitions
 Some symbols are found only on CE products.

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Starting Aid
Battery (Engine) Engine Coolant Engine Oil
(Preheat)

Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)

Certified/Trained
Positive Negative Welding Arc
Mechanic

A Amperes
V Volts
Direct Current
(DC)
Remote

Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature

Air Carbon
Stick (SMAW) TIG (GTAW)
Arc Cutting FCAW Welding
Welding Welding
(CAC-A)

h s 1
Time Hours Seconds Single Phase

3
Read Operator’s
Three Phase Circuit Protection GMAW Welding
Manual

Engine-Driven,
Check Air Cleaner Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz

X Duty Cycle U0 Rated No Load

Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed

n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current

Suitable For Weld-

S P1max
ing In An Environ-
Maximum Power
Air Filter ment With In- Hour Meter
Consumption
creased Risk Of
Electric Shock

Call For Mainten-

ance

OM-247 432 Page 15

 SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Weld, Power, And Engine Specifications

Maximum
Welding Weld Output Rated Welding Open- Auxiliary Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
300 A, 32 Volts DC
40 − 450 A Stick 100% Duty Cycle 72 VDC Stick
CC/DC
20−450A TIG 450 A, 30 Volts DC 61 VDC TIG  Auxiliary power Mitsubishi
40% Duty Cycle not available with Water−Cooled
300 A, 32 Volts DC engine running at Four−Cylinder 35 HP
100% Duty Cycle 3000 RPM. Diesel Engine
CAC-C 40 − 500 A 72 VDC 11 gal
500 A, 30 Volts DC Generator (41.6 L)
Single-Phase, Idle Speed: 1500 RPM
40% Duty Cycle Weld/Power Speed:
4 kVA/kW, 32/16 A,
300 A, 32 Volts DC 120/240 V AC, 1850 RPM
100% Duty Cycle 60 Hz Gouge Speed: 3000
CV/DC 14 − 40 V 61 VDC RPM
450 A, 30 Volts DC
40% Duty Cycle

4-3. Dimensions, Weights, And Operating Angles

Dimensions
32 in. (813 mm)
Height 35-3/4 in. (908 mm) G
(to top of lift eye)
26-1/4 in. (667 mm)
(mtg. brackets turned in)
Width
28-3/4 in. (730 mm)
(mtg. brackets turned out) ! Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth 56 in. (1422 mm)
! Do not move or operate unit where it could
A 56 in. (1422 mm) tip.
B 54 in. (1372 mm) A
B C
C 52 in in. (1321 mm)
D 2 in. (51 mm)
E 26 in. (660 mm)
F 7/8 in. (22 mm)
G 27-3/4 in. (705 mm)
30°
9/16 in. (14 mm) Dia. H
H
4 Holes Front Panel End 30°
20°
Weight 20°
D F
No fuel: 1095 lb (497 kg) E
w/ fuel: 1190 lb (540 kg)

Lifting Eye Weight Rating:

2000 lb (907 kg) Maximum

4-4. Environmental Specifications

IP Rating Operating Temperature Range
IP23S
This equipment is designed for outdoor use. It may be stored, but is −40 to 104°F (−40 to +40°C)
not intended to be used outside during precipitation unless sheltered.

OM-247 432 Page 16

4-5. Duty Cycle And Overheating

1 1 100% Duty Cycle

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

 This unit is rated for welding at

300 amperes continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
600

500
CAC-A
WELD AMPERES

MIG
400
Stick/TIG

300

200
0 10 20 30 40 50 60 70 80 90 100

% DUTY CYCLE
247 394-A

4-6. AC Generator Power Curve

The AC power curve shows the
generator power in amperes.

150 300

125 250

100 200

75 150
AC VOLTS

50 100

25 50

0 0
0 5 10 15 20 25 30 35 40 45 50 55 60

AC AMPERES AT 240 VOLTS AC

0 20 40 60 80 100 120

AC AMPERES AT 120 VOLTS AC

247 396-A

OM-247 432 Page 17

4-7. CC (Stick/TIG) Volt-Ampere Curves
A. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

100

80
DC VOLTS

60 350A−ECONOMY MODE
MAX−POW ER MODE
(GOUGE)
(GOUGE)
40

MAX−POW ER MODE

20 MIN−ECONOMY MODE

0
0 100 200 300 400 500 600

DC AMPERES

B. TIG Mode

100
MAX − POW ER MODE

80

60
DC VOLTS

350A − ECONOMY MODE

40

20

MIN − ECONOMY MODE

0
0 100 200 300 400 500

DC AMPERES

243 460-A / 243 459-A

OM-247 432 Page 18

4-8. CV (MIG/FCAW) Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

100

80
DC VOLTS

60

40

MAX − ECONOMY MODE MAX − POW ER MODE

20
MIN − ECONOMY MODE

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES

247 395-A

4-9. Fuel Consumption

The curve shows typical fuel use
under weld or power loads.

11.36 3.00

10.41 2.75

9.46 2.50

8.52 2.25 POWER MODE

7.57 2.00

6.62 1.75
US Gal./Hr.
Liters/Hr.

5.69 1.50 ECONOMY MODE

4.73 1.25

3.79 1.00

2.84 0.75

1.90 0.50

.95 0.25 IDLE

0.00
0 50 100 150 200 250 300 350 400 450 500

DC W ELD AMPERES AT 100% DUTY CYCLE

243 462

OM-247 432 Page 19

 SECTION 5 − INSTALLATION
5-1. Installing Welding 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

1 1

Tools Needed:
9/16 in. install3 2013-06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

Movement ! Do not weld on base. Welding on 3 1/2 in Bolt And Washer (Minimum −
base can cause fuel tank fire or ex- Not Supplied)
! Do not move or operate unit where
plosion. Weld only on the four
it could tip. 4 3/8-16 x 1 in. Screws (Supplied)
mounting brackets or bolt unit
To Bolt Unit In Place:
 See Section 4-3 for lifting eye rating. down.
NOTICE − Do not mount unit by supporting Remove hardware securing the four
Airflow Clearance mounting brackets to the base. Reverse
the base only at the four mounting brack-
NOTICE − Do not install unit where air flow ets. Use cross-supports to adequately brackets and reattach to base with original
is restricted or engine may overheat. support unit and prevent damage to base. hardware.

Location/Mounting 1 Cross-Supports Mount unit to truck or trailer with 1/2 in. (12
mm) or larger hardware (not supplied).
! Always securely fasten welding 2 Mounting Brackets (Supplied)
To Weld Unit In Place:
generator onto transport vehicle or Mount unit on flat surface or use cross-
trailer and comply with all DOT and supports to support base. Secure unit with Weld unit to truck or trailer only at the four
other applicable codes. mounting brackets. mounting brackets.

OM-247 432 Page 20

5-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

rot_grnd2 2012−03 − 800 652-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.
Exhaust Pipe3 2010−04 / Ref 803 582

OM-247 432 Page 21

5-4. Connecting The Battery

−
+

Tools Needed:
1/2 in.  Shown with rocker
panel removed.

Conn_batt1 2013−04 161-002 / S-0756-C

! Connect negative (−) cable last. necting the battery cables attach the  Never disconnect the battery while
positive (+) cable to the positive (+) the engine is running.
NOTICE − Wait two minutes after engine
shutdown before disconnecting battery or battery terminal first, followed by neg-
 Never use a quick battery charger to
engine controller may be damaged. ative (−) cable to negative (−) battery start the engine.
Battery is accessed through the side door. terminal.
Connect battery, negative cable last.  Do not charge battery with Engine
Close engine access door. Control switch On.
 Never start the engine when the
 Do not allow the battery cables to cables are loose or poorly connected  Always disconnect the negative (−)
touch opposing terminals. When con- to the battery terminals. battery cable before charging battery.

Notes

OM-247 432 Page 22

5-5. Engine Prestart Checks

NOTICE − Follow run-in procedure in

engine manual. If unburned fuel and oil
collect in exhaust pipe, see Section 10.

Full Check radiator coolant

level when fluid is low in
recovery tank.

Diesel
Full

 Engine stops if
fuel level is low.
Capacity:
6 qt (5.7 L)

Coolant Recovery Tank

Hot Full

Cold Full

Full

907 427-6 / 907 427-6-2

 Check all engine fluids daily. Add fresh diesel fuel before starting (see freeze rated to −34° F (−37° C). Add anti-
engine maintenance label for fuel specifica- freeze to mixture if using the unit in tempera-
Engine must be cold and on a level surface. tions). Leave filler neck empty to allow room tures below −34° F (−37° C).
for expansion.
Automatic shutdown system stops engine if Keep radiator and air intake clean and free
oil pressure is too low or coolant tempera-  Engine stops if fuel level is low. of dirt.
ture is too high. Oil NOTICE − Incorrect engine temperature
 This unit has a low oil pressure shut- After fueling, check oil with unit on level sur- can damage engine. Do not run engine with-
down switch. However, some condi- face. If oil is not up to full mark on dipstick, out a properly working thermostat and ra-
tions may cause engine damage before add oil (see maintenance label). diator cap.
the engine shuts down. Check oil level Coolant
often and do not use the oil pressure Check coolant level in radiator before start-
 To improve cold weather starting:
shutdown system to monitor oil level. ing unit the first time. If necessary, add cool-
Use Preheat switch (see Section 6-1).
NOTICE − Diesel engines in MILLER equip- ant to radiator until coolant level is at bottom
ment are meant to operate optimally at mod- of filler neck.
Keep battery in good condition. Store
erate to rated load. Light or no load may Check coolant level in recovery tank daily. battery in warm area.
cause wetstacking or engine damage. If necessary, add coolant to recovery tank
Follow run-in procedure in engine manual. until coolant level is between Cold Full and Use fuel formulated for cold weather
If unburned fuel and oil collect in exhaust Hot Full levels. If recovery tank coolant level (diesel fuel can gel in cold weather).
pipe, see Section 10. was low, also check coolant level in radiator. Contact local fuel supplier for fuel in-
Add coolant if level is below bottom of radia- formation.
Fuel tor filler neck.
NOTICE − Do not use gasoline. Gasoline Unit is shipped with an engine coolant mix- Use correct grade oil for cold weather
will damage engine. ture of water and ethylene glycol base anti- (see Section 8-1).

OM-247 432 Page 23

5-6. Weld Output Terminals

2 3 4
1

247 201-A

1 Negative (−) Weld Output Terminal Electrode Positive (DCEP), connect wire For Direct Current Electrode Negative
2 CV Wire Positive (+) Weld Output feeder cable to Positive (+) terminal and (DCEN), reverse cable connections.
Terminal work cable to Negative (−) terminal. CC TIG Welding
3 CC Stick/TIG Positive (+) Weld Out- For Direct Current Electrode Negative For TIG welding Direct Current Electrode
put Terminal (DCEN), reverse cable connections. Negative (DCEN), connect torch to Negat-
4 CAC-A Positive (+) Weld Output Ter- ive (−) terminal and work cable to Positive
minal CC Stick Welding (+) terminal.
Use Process switch to select type of weld For Stick welding Direct Current Electrode CAC-A Gouging
output (see Section 6-2). Positive (DCEP), connect electrode holder For CAC-A connect electrode holder cable
CV Wire Welding cable to Positive (+) terminal and work to Positive (+) terminal and work cable to
For MIG/FCAW welding Direct Current cable to Negative (−) terminal on left. Negative (−) terminal on left.

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.

1 2  Do not place anything between weld

cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
6 1 Correct Weld Cable Connection
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
4 terminal. Slide weld cable terminal onto
weld output terminal and secure with nut
5 so that weld cable terminal is tight against
copper bar.

Tools Needed:
3/4 in. 803 778-B

OM-247 432 Page 24

5-8. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

Weld Output 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
Terminals
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
! Stop engine before
connecting to weld 2 ea. 2/0 2 ea. 2/0
output terminals. 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
! Do not use worn,
damaged, under- 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
sized, or poorly (2x70) (2x95) (2x95)
spliced cables.
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 2011−07

5-9. Connecting To Remote 14 Receptacle RC14

*The remaining sockets Socket* Socket Information

are not used.

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

24 VOLTS AC A 24 volts AC. Protected by supplementary protector.

B Contact closure to A completes 24 volt AC contactor

control circuit.

C Output to remote control:+10 volts DC in MIG mode;

 Accessories depend 0 to +10 volts DC in Stick or TIG mode.
on unit capabilities. REMOTE D Remote control circuit common.
OUTPUT
CONTROL E DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
OR Adjust control at maximum.

F Current feedback: 1 volt per 100 amperes.

H Voltage feedback: 1 volt per 10 arc volts.

Rmt14_2 GND K Chassis common.
2013−06
NEUTRAL G Circuit common for 24 volt AC circuit.

OM-247 432 Page 25

 SECTION 6 − OPERATING WELDING GENERATOR

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

10 11 12 1 2 3 4

8 9

287 125−A

OM-247 432 Page 26

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

Engine Starting Controls NOTICE − Do not run engine until trouble is 1800 RPM. Auxiliary power is available de-
1 Preheat Switch fixed. pending on welding load.
Use switch to energize starting aid for cold Weld Controls 8 CAC-A / Stick Position
weather starting (see starting instructions fol- 5 Remote Control Receptacle For gouging (CAC-A), place Engine Control
lowing). switch in 350−500 Amps position. The engine
2 Engine Control Switch
 This unit is equipped with 24 volts AC runs at 3000 RPM and auxiliary power is not
control at RC14 protected by supple- available.
Use switch to start engine, select engine mentary protector CB8. For Stick welding, place Engine Control
speed, and stop engine. switch in 20−350 Amps position. The engine
NOTICE − Diesel engines in MILLER equip-
 Remote controls requiring 24 volts AC runs at 1500 RPM at no load and 1800 RPM
ment are meant to operate optimally at mod- connected to the receptacle do not oper- while welding. Auxiliary power is available de-
erate to rated load. Light or no load may cause ate when the Engine Control switch is in pending on welding load.
wetstacking or engine damage. the 350-500 Amp position.
9 Scratch Start TIG Position
To Start: Use receptacle to connect remote controls, In this position, with Engine Control switch in
wire feeders, and tools. 20−350 Amps position, the engine runs at
NOTICE − Do not use ether.
When a remote control is connected to the 1800 RPM. Auxiliary power is available de-
 If engine does not start, let engine come Remote receptacle, the Auto Sense Remote pending on welding load.
to a complete stop before attempting re- feature automatically switches voltage/am- 10 Voltage/Amperage Control
start. perage control to the remote control (see Sec-
tion 5-9). With Process switch in any Stick or TIG set-
Above 325 F (05 C): turn Engine Control ting, use control to adjust amperage. With
switch to Start. Release Engine Control With remote control connected, weld output is Process switch in CV (wire feed) position, use
switch when engine starts. determined by a combination of front panel control to adjust voltage.
and remote control voltage/amperage set-
Below 325 F (05 C): turn engine control switch Weld Meters (Optional)
tings.
to 350−500 Amps position. Push Preheat
switch up for 30 seconds. Turn Engine Con- If no remote control is connected to the Re-  Weld meters also work in combination to
trol switch to Start. Release Engine Control mote receptacle, the front panel Voltage/Am- display troubleshooting help codes (see
switch and Preheat switch when engine perage control adjusts voltage and amper- Section 8-10).
starts. age. 11 DC Voltmeter
To Stop: turn Engine Control switch to Off  If a remote device connected to Remote Voltmeter displays preset voltage (FCAW
position. Receptacle RC14 is faulty or is discon- welding) until an arc is struck, and actual out-
nected during operation, the optional put voltage while welding. Voltmeter displays
Engine Gauges, Meters, And Lights voltage at the weld output terminals, but not
meters display Help 25 (see Section
 See Section 6-5 for complete fuel/hour 8-10). Clear fault by stopping and restart- necessarily the welding arc due to resistance
of cable and connections.
gauge information. ing the unit or by turning Process switch
to another position. To set voltage, turn Process switch to CV
3 Fuel Gauge/Hourmeter position. Turn V/A control until desired volt-
6 Process Switch
Use gauge to check fuel level or total engine age is displayed on Voltmeter. When welding
operating hours, or hours to oil change. Use switch to select weld process. is finished, voltmeter displays weld voltage
To check fuel level or engine hours when en- ! Weld output terminals are energized and then defaults to preset voltage.
gine is not running, turn Engine Control switch when the engine is running. 12 DC Ammeter
to 20−350 Amps position. Ammeter displays preset amperage (Stick
4 Engine Indicator Light
 For welding, it is recommended that the and TIG only) when not welding, and actual
Engine Control switch be in the 20−350 output amperage when welding.
Light goes on and engine stops if engine tem- Amps position. For gouging, place
perature exceeds 230° F (110° C) or engine Engine Control switch in 350−500 Amps To set amperage, turn Process switch to Stick
oil pressure is below 10 psi (69 kPa). position. or TIG position. Turn V/A control until desired
amperage is displayed on Ammeter. When
 Normal engine temperature is 180 - 203 7 CV (Wire Feed) Position welding is finished, ammeter displays weld
F (82 - 95 C). Normal oil pressure is 30 In this position, with Engine Control switch in amperage and then defaults to preset amper-
- 60 psi (207 - 414 kPa). 20−350 Amps position, the engine runs at age.

OM-247 432 Page 27

6-3. Remote Voltage/Amperage Control

1 Remote 14 Receptacle RC14

Connect optional remote control to RC14 (see
Section 5-9).
1  Remote controls requiring 24 volts AC con-
nected to the receptacle do not operate
when the Engine Control switch is in the
350-500 Amp position.
2 3  When a remote control is connected to the
Remote receptacle, the Auto Sense Re-
mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process switch.
2 Voltmeter
3 Ammeter

Example: Combination Remote Voltage Control

Voltmeter Toggles Between In Example:

28
Ammeter Shows Zero
Preset And Actual Output
When Not Welding, Actual
Voltage While Welding
0 Process = Remote CV
Min = 16 V DC
Max = 40 V DC

Max (40 V DC)

Min (16 V DC)

Connect Remote Set Process V/A Control setting does Adjust Optional Remote Control
Control To Remote not matter
Receptacle RC14

Example: Combination Remote Amperage Control (TIG)

Voltmeter Shows Open-Circuit Ammeter Shows Preset

Voltage When Not Welding, Arc
Voltage While Welding 56 205 Output When Not Welding,
Actual Amperage While
Welding
In Example:
Process = Remote TIG
Min = 20 A DC
Max = About 250 A DC

Max (250 A DC)

Min (20 A DC)

Connect Remote Set V/A Control

Set Process Adjust Optional Remote Control
Control To Remote Mid-Range: About 250 A
Receptacle RC14

0774 / Ref.287 125−A / Ref 804 444−A

OM-247 432 Page 28

6-4. Operating Optional Engine Block Heater
1 Engine Block Heater Plug
Use heater to maintain a constant
engine coolant temperature.
To turn on heater, connect heater
Coolant Heater
plug to 120 volts AC receptacle.
Specifications
! Do not run engine while en-
Watts Volts ±10% gine block heater is on.
NOTICE −In extremely cold weath-
400 120 er, heater should be connected to
120 volts AC receptacle when en-
gine is warm.
! The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.

Coolant Heater1 2012−05 803 562 / Ref. 803 145

Notes

OM-247 432 Page 29

6-5. Fuel/Hour Gauge Descriptions

OM-247 432 Page 30

 SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

1 2 3 4 5

245 609

! Use GFCI protection when operat- ! Test GFCI monthly. See Section 7-2 overload. If CB5 opens, the receptacles do
ing auxiliary equipment. If unit does for GFCI information and for reset- not work. Place CB5 switch in On position
not have GFCI receptacles, use ting and testing procedures. to reset circuit breaker.
GFCI-protected extension cord. Do
not use GFCI receptacle to power
2 240 V 50 A AC Receptacle RC11  If a supplementary protector continues
life support equipment. RC11 supplies 60 Hz single-phase power to open, contact Factory Authorized
at weld/power speed. Maximum output Service Agent.
from RC11 is 10 kVA/kW.
! Unplug power cord before attempt-
 Generator power decreases as weld
ing to service accessories or tools. 3 Supplementary Protector CB4
output increases.
4 Supplementary Protector CB6
1 120 V 20 A AC GFCI Receptacles Combined output of all receptacles is lim-
5 Supplementary Protector CB5
GFCI1 And GFCI2 ited to the 10 kVA/kw rating of the generator.
CB4 protects GFCI2 and CB6 protects
GFCI1 from overload. If a supplementary EXAMPLE: If 15 A is drawn from each 120
GFCI1 and GFCI2 supply 60 Hz
protector opens, the receptacle does not V receptacle , only 26 A is available at the
single-phase power at weld/power speed.
work. Press button to reset. 240 V receptacle:
Maximum output from these receptacles is Supplementary protector CB5 protects re- 2 x (120 V x 15 A) + (240 V x 26 A) =
2.4 kVA/kW. ceptacles and the generator winding from 10.0 kVA/kW

OM-247 432 Page 31

7-2. GFCI Receptacle Information, Resetting And Testing

4
! Test and reset GFCI only at Run
speed.

RotGFCI1 2012−05

! Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords,
ing auxiliary equipment. If unit does button pops out, and the circuit opens to plugs, etc. connected to the receptacle.
not have GFCI receptacles, use disconnect power to the faulty equipment. Start engine and operate at Run (weld/
GFCI-protected extension cord. Do A GFCI receptacle does not protect against power) speed. Press GFCI Reset button.
not use GFCI receptacle to power circuit overloads, short circuits, or shocks Reconnect equipment to GFCI receptacle.
life support equipment. not related to ground faults. Reset and test If GFCI Reset button pops out again, check
GFCI receptacle according to the following the equipment and repair or replace if faulty.
! Unplug power cord before attempt- procedures.
Testing GFCI Receptacles
ing to service accessories or tools. Resetting/Testing GFCI Receptacle
1 120 V 20 A AC GFCI Receptacle ! Test GFCI monthly. See Testing  GFCI testing must be done with engine
GFCI Receptacle. running at Run (weld/power) speed.
2 GFCI Receptacle Test Button
! Do not test or reset GFCI recept- Start engine and operate at Run (weld/
3 GFCI Receptacle Reset Button power) speed.
acles at idle speed/low voltage or
4 GFCI Indicator Light (LED) the GFCI will be damaged and not Press the GFCI Test button. The GFCI Re-
provide protection from electric set button should pop out.
GFCI Receptacles shock caused by a ground fault.
Press the GFCI Reset button.
GFCI receptacles protect the user from ! If LED blinks, stop using GFCI re-
electric shock if a ground fault occurs in ceptacle and have it replaced by a Have GFCI replaced by a Factory Au-
equipment connected to the receptacle. A Factory Authorized Service Agent. thorized Service Agent if any of the fol-
ground fault occurs when electrical current lowing occur:
takes the shortest path to ground (which Resetting GFCI Receptacles GFCI does not trip when tested
could be through a person) rather than fol- If a GFCI fault occurs, stop engine and dis- LED blinks
low its intended safe path. connect equipment from GFCI receptacle. GFCI does not reset.

OM-247 432 Page 32

 SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label

Mitsubishi Engine North America

1250 Greenbriar Dr., Suite E
Addison, IL 60101
630−268−0750
Http://www.mitsubishi−engine.com
Use web site to locate closest dealer. For in-
ternational information, use:
Http://www/mhi/co/jp/global/network

OM-247 432 Page 33

8-2. Routine Maintenance
! Stop engine before maintaining.

Recycle engine
 See Engine Manual and Maintenance Label
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 Section 5-5,
8 8-7
Hours

 Coolant Level  Fuel Level  Oil Level  Oil, Fuel Spills

Every
50
Hours

 Weld Terminals
Every Section 8-3
100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element  Unreadable Labels
Every NOTICE − Change engine Engine
500 1/2 in.
(13 mm) oil and filter after initial 50 to Manual,
Hours 75 hours of use. Section 8-5,
8-7

 Weld Cables  Fan Belt Tension  Oil  Oil Filter Spark Arrestor

 Inline Fuel Filter  Fuel Filter Radiator Thermostat

Every Section 5-5,
FUEL
1000 8-4, 8-6,
OR
Hours 8-7, and
Engine
SLUDGE Manual
Radiator Fluid Level  Inside Unit Valve Clearance*  Drain Sludge

 Slip Rings*
 Brushes*
Every
2000
Hours

 Injectors*

OM-247 432 Page 34

8-3. Servicing Air Cleaner

1 2 3 4

Optional

Blow Inspect

Keep nozzle 2 in.

(51 mm)
from element.

aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B

! Stop engine. ment, we strongly recommend instal- To clean air filter:

ling an optional safety element to pro-
Wipe off cap and housing. Remove cap
NOTICE − Do not run engine without air vide additional engine protection. Nev-
and dump out dust. Remove element(s).
cleaner or with dirty element. Engine dam- er clean a safety element. Replace
Wipe dust from inside cap and housing
age caused by using a damaged element the safety element after servicing the
with damp cloth. Reinstall safety element
is not covered by the warranty. primary element three times.
(if present). Reinstall cap.
 The air cleaner primary element can Clean or replace primary element if dirty
(see note above before cleaning). Replace
NOTICE − Do not clean housing with air
be cleaned but the dirt holding capacity hose.
primary element if damaged. Replace pri-
of the filter is reduced with each clean- Clean primary element with compressed
mary element yearly or after six cleanings.
ing. The chance of dirt reaching the air only.
clean side of the filter while cleaning 1 Housing
and the possibility of filter damage Air pressure must not exceed 100 psi (690
makes cleaning a risk. Consider the 2 Safety Element (Optional) kPa). Use 1/8 in. (3 mm) nozzle and keep
risk of unwarrantable equipment dam- nozzle at least 2 in. (51 mm) from inside of
age when determining whether to 3 Primary Element element. Replace primary element if it has
clean or replace the primary element. holes or damaged gaskets.
4 Dust Cap
Reinstall primary element and cap (dust
 If you decide to clean the primary ele- 5 Dust Ejector ejector down).

OM-247 432 Page 35

8-4. Checking Generator Brushes

! Stop engine and let cool.

1 Generator Brush Assembly
Mark and disconnect leads at brush hold-
er assembly. Remove assembly. Press
Replace Assembly if on brush to be sure springs compress.
1 Brushes are Damaged 1 Replace assembly if brushes are dam-
aged or if brush material is at or near mini-
mum length. Check length from brush-
New Length: holder surface.
5/8 in. (16mm)
Minimum Length:
1/4 in. (6.5mm)

GenBrush2 2013-03 / Ref 205 725

8-5. Inspecting And Cleaning Spark Arrestor Muffler

! Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
3 blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
! Stop engine and let cool.
1
Reinstall cleanout plug.

Tools Needed:
3/8 in.

907 427-2

OM-247 432 Page 36

8-6. Servicing Engine Cooling System

! Stop engine and let cool.

1 Radiator Cap Cover
2 Radiator Draincock
3 Coolant Recovery Tank
Change coolant according to engine
manual. Add coolant according to engine
maintenance label.
Check coolant level in recovery tank dai-
ly. If necessary, add coolant to recovery
tank until coolant level is between Cold
Full and Hot Full levels. If recovery tank
coolant level was low, also check coolant
level in radiator. Add coolant if level is be-
1 low bottom of radiator filler neck.

Coolant1 2010−04 / Ref. 907 427-6

Notes

OM-247 432 Page 37

8-7. Servicing Fuel And Lubrication Systems

! Stop engine and let cool.

! After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
Location
5 Fuel Filter Retaining Ring
6 Secondary (In-Line) Fuel
Filter
7 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary (canister) fuel
filter:
Turn filter retaining ring counter-
clockwise to remove. Pull filter
2 straight down to remove.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and reinstall re-
taining ring.
Inspect fuel lines, and replace if
6 cracked or worn.
To drain water from fuel system:
7 See engine manual.
Tools Needed:
To replace secondary (in-line)
fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
place filter, reconnect fuel lines, and
4 reinstall clamps.
3
To drain sludge from fuel tank:
! Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
! Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.

1 5
Ref. 804 009−C / 907 427-6

OM-247 432 Page 38

8-8. Overload Protection

! Stop engine.

 When a circuit breaker, supple-

mentary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2 Circuit Breaker CB1 (Not
Shown)
3 Supplementary Protector CB2
4 Supplementary Protector CB3
1 5 Supplementary Protector CB8
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
3 opens, 24 volt output to RC14 stops.
Press button to reset supplementary
protector.

Ref. 803 566 / Ref. 804 009-F

OM-247 432 Page 39

8-9. Adjusting Engine Speed
 The engine is electronically governed. Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with
adjustments may affect engine warranty.

8-10. Voltmeter/Ammeter Help Displays (Models With Optional Meters)

HL.P 20
2

HL.P 21
3

HL.P 22
4

HL.P 23
5

HL.P 25

Use the Voltmeter/Ammeter help displays Indicates thermal protector TP1 on stabil- 4 Help 23 Display
to diagnose and correct fault conditions. izer Z1 has opened (Z1 overheated) or Can indicate a complete loss of generator
thermistor TH1 on the main rectifier heat excitation, auxiliary power output, and
 When a help code is displayed normal- sink has failed. If this display is shown, al- weld output or a failure of one of the rectifier
ly weld output has stopped but genera- low unit to cool and reduce duty cycle. If output SCRs. If generator output is lost,
tor power output may be okay. unit does not reset after cooling, have Fac- see trouble “No generator power or weld
tory Authorized Service Agent check TH1, output.” in section 8-11B. If generator out-
put is okay, have Factory Authorized Ser-
 To reset help displays, stop unit and and the wiring between TH1 and PC1.
vice Agent check the rectifier SCRs.
then restart. See item 6 below to reset
3 Help 22 Display 5 Help 25 Display
Help 25 display.
Indicates a remote device connected to
1 Help 20 Display Indicates the rectifier heat sink has over- Remote Receptacle RC14 may be faulty.
heated. If this display is shown, check gen- Help 25 is also displayed whenever a re-
Indicates a failure of meter display module mote device has been connected to RC14
erator cooling system and/or reduce duty
PC2, or the wiring between PC2 and main and then disconnected. Clear fault by stop-
cycle. Keep engine access door closed
control module PC1. If this display is ping and restarting the unit or by turning
shown, have Factory Authorized Service when running to maintain proper cooling Process/Contactor switch to another posi-
Agent check PC1, PC2, and the wiring be- air flow past rectifier. Allow unit to cool be- tion. If problem continues, have Factory
tween PC1 and PC2. fore restarting. If problem continues, have Authorized Service Agent check the re-
Factory Authorized Service Agent check mote device, filter board PC6, and main
2 Help 21 Display unit. control module PC1.

OM-247 432 Page 40

8-11. Troubleshooting

 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).

A. Welding

Trouble Remedy

No weld output; generator power output Have Factory Authorized Service Agent check main rectifier and main control module PC1.
okay at AC receptacles.

Reset supplementary protector CB8 (see Section 8-8). Check for faulty remote device connected to
RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).

Check Voltmeter/Ammeter help displays (see Section 8-10).

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

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

Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.

Check Voltmeter/Ammeter help displays (see Section 8-10).

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

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

Low weld output. Have engine Factory Authorized Service Agent check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
Agent check the rotor.

Low open-circuit voltage. Have engine Factory Authorized Service Agent check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).

No 24 volt AC output at Remote recep- Reset supplementary protector CB8 (24 volt) (see Section 8-8).
tacle RC14.

OM-247 432 Page 41

B. Standard Generator Power

Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1). Check and reset GFCI receptacles if ne-
tacles; weld output okay. cessary (see Section 7-2).

Change engine control switch to 20−350 Amps position.

No generator output and remote con- Have Factory Authorized Service Agent check time delay relay TD1.
trol does not work.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check field
excitation circuit.

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

Check Voltmeter/Ammeter help displays (see Section 8-10).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC re- Have Factory Authorized Service Agent check field excitation circuit.
ceptacles.

Low output at generator power AC re- Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
ceptacles. Agent check the rotor.

Have engine Factory Authorized Service Agent check engine speed, and adjust if necessary.

C. Engine

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

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-8).
Have Factory Authorized Service Agent check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 8-8).

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1, Fuel/Hour gauge FUEL/HM,
and control relay CR2.

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 CR1, fuel pump, and Fuel/Hour gauge
FUEL/HM.

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Preheat switch S4 (see Section 6-2).

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

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

Use correct grade oil for cold weather (see Section 8-1).

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-5 ).

Check fuel/hour meter for indication of shutdown.

Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Section
8-8). Have Factory Authorized Service Agent check engine alternator, fuel pump, and engine har-
ness.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-
grated rectifier SR2, and the fuel pump.

See engine manual.

OM-247 432 Page 42

 Trouble Remedy
Engine slowly stopped and cannot be Check fuel level.
restarted.

Check fuel/hour gauge FUEL/HM for indication of shutdown.

Check engine air and fuel filters (see Sections 8-3 and 8-7).

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 engine speed control system.
weld speed.

Engine does not run at idle speed. Have engine Factory Authorized Service Agent check engine speed control system.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.

Notes

Work like a Pro!

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

OM-247 432 Page 43

 SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

OM-247 432 Page 44
 260 876-B

OM-247 432 Page 45

 SECTION 10 − RUN-IN PROCEDURE
run_in1 2013−06

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.

10-1. Wetstacking
NOTICE − Do not perform run-in
2
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welding 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.
1 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welding genera-
tor is kept loaded during run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.

OM-247 432 Page 46

10-2. Run-In Procedure Using Load Bank Or Resistance Grid

2
1

4
3

S-0683 / S-0684

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

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

OM-247 432 Page 47

 SECTION 11 − GENERATOR POWER GUIDELINES
 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. 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 in-
sulated.

2 3

OR

gen_pwr 2012−03 − ST-800 577

11-2. 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) welding generator from the vehicle life support equipment..

OM-247 432 Page 48

11-3. 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

11-4. 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 approxi-
mately six times more power while
starting the motor than when running
3 (see Section 11-8).
VOLTS 115 3 Rating Data
2 AMPS 4.5
1 Hz 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 run-
ning 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-247 432 Page 49

11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts
Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050

OM-247 432 Page 50

11-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-247 432 Page 51

11-8. 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).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting 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

11-9. 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-247 432 Page 52

11-10. 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
1 2 3 4 operate this equipment ac-
Fused cording to its Owner’s Manu-
Utility Welding al and national, state, and lo-
Disconnect
Electrical Transfer Switch Generator cal codes.
Switch
Service Output
(If Required)
 Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
ages.
5 1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Essential
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 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low 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 11-4).

OM-247 432 Page 53

11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

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

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

Current
Load (Watts) 4 6 8 10 12 14
(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 (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(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-247 432 Page 54
Notes

OM-247 432 Page 55

 SECTION 12 − PARTS LIST
 Hardware is common and not
available unless listed.

Wiring harnesses are listed at

the end of parts section.
107

108

109

7
9
10
8

907 427−3 15
5
104 103

101 99 14
105 13
102 100
11 12
4

3 97
98
95 96
106 94
1
93
2
75

91

92 76
90 77
81 78

79 − Not Shown
82
84
83
86
85
80
87
88

89

Ref: 907 426−8A

Figure 12-1. Main Assembly

OM-247 432 Page 56
 21 22
19

23
18
29
20
28
26 27
17

25
24

16

66
67 31 30
48 47
65
49
46 32
36 38
37
64 50 51 43
73 35 39
45 44 34
52 40
63 33
74 72 54 53
55
56 41
71
57
62 59
58
60 42
70 61
69

68

907 427−10A

OM-247 432 Page 57

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

Figure 12-1. Main Assembly

. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 12-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . Figure 12-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . . . . +243709 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 232425 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . PC1 . . . . 256555 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . T1 . . . . . 232445 . . Xfmr, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 259211 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 241264 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 209057 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 13 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . . 17 . . . . . . . . . . . . . +249656 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 18 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . +243710 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 243711 . . Panel, Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 243698 . . Radiator, W/14# Cap 1 Row Core 1.250 Inlet/Outlet . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 222652 . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 239396 . . Label, Diesel Engine Maintenance Mitsubishi S4L2 . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 245362 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 40 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . . . 243708 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . +241176 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 45 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 241286 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 241266 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 241256 . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 242883 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-247 432 Page 58

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

Figure 12-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 51 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 236978 . . Ftg, Adapter Oil Drain Mitsubishi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 244218 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 56 . . . . . . . . . . . . . . 243950 . . Bracket, Mtg Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . *252781 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 241265 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 243950 . . Bracket, Mtg Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 242538 . . Actuator, Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 243763 . . Nut, M30x1.5 Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 62 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . Figure 12-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 242642 . . Engine, Mitsubishi Dsl Elec S4L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *242882 . . Filter, Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 252782 . . Kit, Filter Mitsubishi (S4l2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 244039 . . Switch, Coolant Temp N.C. 111c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 244040 . . Switch, Lubricating Oil Pressure N.c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦245836 . . Heater, Block Engine 115v 400w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 249550 . . Bracket, Mtg Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 241272 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 249657 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249661 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249659 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249658 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249664 . . . . Latch, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 227643 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . SENDER . . 235191 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 76 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 78 . . . . BATT . . . . . . . . . . . . . . Battery, Stor 12v 550 Crk 95 Rsv Gp 35 Maint Free . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 261792 . . Bracket, Battery Holddown (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 82 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . R4 . . . . . 189699 . . Resistor, Ww Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 226150 . . Label, Ce Sound Power Level 96db . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . Figure 12-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . CT1 . . . . 105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-247 432 Page 59
. . . 92 . . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Card 907427 (Order By Model And Serial No.) . . . . . . . . . . 1
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly (Continued)

. . . 93 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 94 . . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 261784 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . . 245752 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 285297 . . Adapter, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . TE1, TE2 . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 102 . . . . C11 . . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . Z1 . . . . . 247496 . . Stabilizer (Without Thermostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . TP1, TP2 . . 244183 . . Thermostat, NC Open 180F Close 155F Flange Faston . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 104 . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . 6
. . 105 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . ♦244508 . . Pipe, Exhaust Spark Arresstor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . ♦088528 . . Spark Arrestor, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . ♦244507 . . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 238650 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218460 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-247 432 Page 60

  Hardware is common and not
available unless listed.

11 Wiring harnesses are listed at

10 the end of parts section.
12

8 9

13
7 14
15

5 16 24
23
4 17 22
23
3 25
1 2 18 21 26 27
37
19
36
20

35

28
29
30
31
34
32 907 426-12A

33

Figure 12-2. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 90 )

... 1 . . . . . . . . . . . . . . 218764 . . Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . PC6 . . . . 242263 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CB8 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 247190 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 214762 . . Bracket, Meter Hole Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . ♦214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . ♦134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
... 12 . . . . PC2 . . ♦242527 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . R1 . . . . . 242793 . . Switch, Rotary 3 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . . 1
... 14 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

OM-247 432 Page 61

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

Figure 12-2. Panel, Front w/Components (Continued)

. . . 16 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 C13, 14, 15,16 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 246765 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . GFCI1, 2 . . 246614 . . Rcpt, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . C11,12 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . RC11 . . . . 147632 . . Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . CB4, CB6 . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . CB5 . . . . 201083 . . Supplementary Pro, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 34 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 35 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . FUEL/HM . . 246181 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-247 432 Page 62

 3 4
2
 Hardware is common and not
available unless listed.
5
Wirng harnesses are listed at
the end of parts section.

1
6

7
15

14

8
10

11

16

12 242 269-B
13
Figure 12-3. Control Panel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-3. Control Panel (Figure 12-1 Item 2)

. . . 1 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . CR1 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . CR8 . . . . 044588 .. Relay, Encl 12vdc 3pdt 10a/120vac 11pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . 4 . . CR5, CR9 . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . 2
... 5 .............. 285300 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
. . . 9 . . . . TE3 . . . . 190210 .. Block, Term 5−3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . D1 . . . . . 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 242295 .. Module, Control Governor (Programed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . SR1,2,4,5 . . 245446 .. Rectifier, Integ Bridge 1ph 35. Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . VR1 . . . . 245944 .. Varistor, 1200v 700 Joule W/Terminals (on SR5 AC Terminals) . . . . . . . . 1
. . . 13 . . CB2, CB3 . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
.................... 190323 .. Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . CR4, CR7 . . 173069 .. Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR2 . . . . 252053 .. Relay, Encl 12vdc Spst 35a/14vdc 5 Pin (in Wiring Harness) . . . . . . . . . . 1
. . . 16 . . . . TD1 . . . . 260836 .. Timer, Delay On Make 3 Sec 12vdc/1amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-247 432 Page 63

 7
 Hardware is common and not
available unless listed.

Wiring harnesses are listed at

the end of parts section.
6
5
4

1
3

2 8

17

9
16 10

11
14 15

13

12
907 427-13

Figure 12-4. Generator

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

Figure 12-4. Generator (Figure 12-1 Item 63)

... 1 . . . ROTOR . . . 243820 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 181143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 243986 . . Screw, M12−1.25x 40 Hex Hd−pld Blk Grd 5 . . . . . . . . . . . . . . . . . . . . . . . . 7
... 6 .............. 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . 7
... 7 .............. 242537 . . Pickup, Magnetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 241075 . . Adapter, Engine Machined Mitsubishi S4l2 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 10 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 11 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 12 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 13 .............. 136343 . . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . 2
... 14 .............. 244290 . . Brushholder Assy, Generator W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 183419 . . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 183336 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . STATOR . . 247444 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-247 432 Page 64

 Hardware is common and not
available unless listed. 6
1
Wirng harnesses are listed at
the end of parts section.

3
2

10

9
803 685-A

Figure 12-5. Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4)

.................... 217081 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . MOD1,2,3 . . 218296 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . MOD4,5,6 . . 218292 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .............. 212602 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212639 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 .............. 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . RT1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . C7,8,9 . . . 048420 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-247 432 Page 65
 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part

No. Mkgs. No. Description Quantity

Wiring Harnesses

.................... 260875 .. Harness, Engine/Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S1 . . . . . 177859 .. Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 214932 .. Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 1
. . . . . . . . PLG1, 3, 6 . 214933 .. Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . PLG2 . . . . 150316 .. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
.................... 231708 .. Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG3, 7 . . 214934 .. Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . PLG5 . . . . 113750 .. Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 214951 .. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 .. Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 196602 .. Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . PLG7 . . . . 193183 .. Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 215340 .. Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg . . . . . . . . . . . . . . . . . 1
.................... 217000 .. Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 242288 .. Harness, Governor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 246562 .. Boot, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

.................... 214984 . . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
.................... 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 247064 . . Harness, Receptacle Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 242811 . . Harness, Lead Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-247 432 Page 66

 Effective January 1, 2013
(Equipment with a serial number preface of MD 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. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
for your local workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Guns
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service
followed. * Replacement Parts (No labor)
You always get the fast,
reliable response you Miller shall honor warranty claims on warranted equipment listed * Roughneck Guns
need. Most replacement below in the event of such a failure within the warranty time periods. * Spoolmate Spoolguns
parts can be in your All warranty time periods start on the delivery date of the equipment Miller’s True Blue® Limited Warranty shall not apply to:
to the original end-user purchaser, and not to exceed one year after 1. Consumable components; such as contact tips,
hands in 24 hours. the equipment is shipped to a North American distributor or eighteen
cutting nozzles, contactors, brushes, relays, work
Support months after the equipment is shipped to an International distributor.
station table tops and welding curtains, or parts that
Need fast answers to the 1. 5 Years Parts — 3 Years Labor fail due to normal wear. (Exception: brushes and
tough welding questions? * Original Main Power Rectifiers Only to Include SCRs, relays are covered on all engine-driven products.)
Contact your distributor. Diodes, and Discrete Rectifier Modules 2. Items furnished by Miller, but manufactured by others,
The expertise of the 2. 3 Years — Parts and Labor such as engines or trade accessories. These items are
distributor and Miller is * Auto-Darkening Helmet Lenses (Except Classic covered by the manufacturer’s warranty, if any.
there to help you, every Series) (No Labor) 3. Equipment that has been modified by any party other than
step of the way. * Engine Driven Welding Generators Miller, or equipment that has been improperly installed,
(NOTE: Engines are Warranted Separately by the improperly operated or misused based upon industry
Engine Manufacturer.) standards, or equipment which has not had reasonable
* Inverter Power Sources (Unless Otherwise Stated) and necessary maintenance, or equipment which has
* Oxy-Fuel Cutting Torches (No Labor) been used for operation outside of the specifications for
* Plasma Arc Cutting Power Sources the equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Semi-Automatic and Automatic Wire Feeders TRAINED AND EXPERIENCED IN THE USE AND
* Smith Series 30 Flowgauge, Flowmeter, and Pressure MAINTENANCE OF WELDING EQUIPMENT.
Regulators (No Labor) In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Water Coolant Systems (Integrated) replacement; or, where authorized in writing by Miller in appropriate
3. 2 Years — Parts and Labor cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
* Auto-Darkening Helmet Lenses − Classic Series Only purchase price (less reasonable depreciation based upon actual
(No Labor) use) upon return of the goods at customer’s risk and expense.
* Fume Extractors − Filtair 400 and Industrial Collector Miller’s option of repair or replacement will be F.O.B., Factory at
Series Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
4. 1 Year — Parts and Labor Unless Specified as determined by Miller. Therefore no compensation or
* Automatic Motion Devices reimbursement for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor) TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Field Options DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
(NOTE: Field options are covered for the remaining CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
warranty period of the product they are installed in, or WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
for a minimum of one year — whichever is greater.) LEGAL THEORY.
* Flowgauge and Flowmeter Regulators (No Labor) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* HF Units BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* ICE/XT Plasma Cutting Torches (No Labor) OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
* Induction Heating Power Sources, Coolers DEALING, INCLUDING ANY IMPLIED WARRANTY OF
(NOTE: Digital Recorders are Warranted Separately MERCHANTABILITY OR FITNESS FOR PARTICULAR
by the Manufacturer.) PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
* Motor Driven Guns (except Spoolmate Spoolguns)
Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor)
implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
* Water Coolant Systems (Non-Integrated) additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
* Weldcraft-Branded TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2013-01
 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. Co.
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 © 2013 Miller Electric Mfg. Co. 2013−01