Miller Welding Service manual

Safety Quick-Guide
For Arc
Welding
and Cutting
the
Safe Way!
Visit our websites at
www.MillerWelds.com
www.HobartWelders.com
Be sure this guide reaches the operator.

Page 1
Safety Quick-Guide
Thank you for using Miller or Hobart arc welding and cut-
ting equipment.
We ask you to work like a pro and pros weld and cut safely. Please
read and comply with the sample safety procedures outlined in this
guide and the equipment Owner’s Manual.
Always read and follow the Owner’s Manual, the safety labels on the
product, and all applicable safety standards, especially ANSI Z49.1,
Safety in Welding, Cutting, and Allied Processes (we recommend you
get a copy and keep it handy). A list of the safety standards and where
to get them is located in Section 7 of this guide.
Thank you for working safely.
CONTENTS
1. General Safe Practices 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Arc Welding Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Engine Hazards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Plasma Arc Cutting Hazards 6. . . . . . . . . . . . . . . . . . . . . . . .
5. Trailer Safety 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Special Situations & Equipment 11. . . . . . . . . . . . . . . . . . . . .
7. Principal Safety Standards 12. . . . . . . . . . . . . . . . . . . . . . . . .
8. Lens Shade Selector Guide 13. . . . . . . . . . . . . . . . . . . . . . . . .
9. Weld Cable Selector Guide 14. . . . . . . . . . . . . . . . . . . . . . . . .

Page 2
Safety Quick-Guide
1. General Safe Practices
Become trained and read the
instructions before working on the
machine or welding or cutting
.
Read Material Safety Data Sheet
s
(MSDSs) for metals, consum
-
ables, and coatings.
+
ANSI Z49.1
OSHA29CFR 1910
MSDSs
Owner’s Manual
Wear approved safety glasses with side shields under you
r
welding helmet or face shield and at all times in the work area.
Read the equipment Owner’s Manual for more complete safet
y
information.
Wear a safety harness if working above floor level.
Keep children away from all equipment and processes.
Do not install or place machine on or over combustible surfaces
.
Have only qualified persons install, use, or service all equipment
.
2. Arc Welding Hazards
Electric shock from welding electrode or wiring
can kill.
Wear dry insulating gloves. Do not touch electrode with bare hand.
Do not wear wet or damaged gloves.
Do not touch live electrical parts.
Do not use AC weld output in damp, wet, or confined spaces.
Protect yourself from electric shock by insulating yourself from
work and ground. Use non-flammable, dry insulating material if
possible, or use dry rubber mats, dry wood or plywood, or other dry
insulating material big enough to cover your full area of contact
with the work or ground, and watch for fire.
Disconnect input plug or power before working on machine.
Do not make input connections if color blind.
Frequently inspect input power cord for damage or bare wiring —
repair or replace cord immediately if damaged. Be sure input
ground wire is properly connected to a ground terminal in
disconnect box or receptacle.
Properly install and ground all equipment according to its Owner’s
Manual and national, state, and local codes.

Page 3
Safety Quick-Guide
Use a ventilating fan to remove fumes from the breathing zone and
welding area.
If adequacy of ventilation or exhaust is uncertain, have your
exposure measured and compared to the Threshold Limit Values
(TLV) in the Material Safety Data Sheet (MSDS).
Keep your head out of the fumes. Do not breathe the fumes. Use
enough ventilation, exhaust at the arc, or both, to keep fumes and
gases from your breathing zone and the general area.
Read Material Safety Data Sheets (MSDSs) for metals, consum-
ables, and coatings.
Use enough forced ventilation or local exhaust (forced suction) at
the arc to remove the fumes from your breathing area.
Breathing welding fumes can be hazardous to
your health.
Do not weld on drums, tanks, or any closed containers unless a
qualified person has tested it and declared it or prepared it to be
safe (see AWS F4.1 listed in Section 7).
Do not weld near flammable material. Move flammables at least 35
feet (11 meters) away or protect them with flame-proof covers (see
NFPA 51B listed in Section 7).
Welding sparks can cause fires. Have a fire extinguisher nearby,
and have a trained fire watch ready to use it.
Welding can cause fire or explosion.

Page 4
Safety Quick-Guide
Wear complete body protection. Wear oil-free protective clothing
such as leather gloves, heavy shirt, cuffless pants, and high boots.
Wear welders cap and safety glasses with side shields. Use ear
protection when welding out of position or in confined spaces.
Button shirt collar.
Use welding helmet with correct shade of filter (see Section 8 to
choose the correct shade).
Arc rays can burn eyes and skin.
3. Engine Hazards
Engine fuel plus flames or sparks can cause fire or explosion.
Do not weld near engine fuel.
Do not spill fuel. If fuel is spilled, clean it up and do not start engine
until fumes are gone.
+ =
Do not smoke while fueling or if near fuel or fumes.
Stop engine before fueling.
Do not fuel a hot engine. Stop engine and let it cool off before
checking or adding fuel.
Fuel can cause fire or explosion.

Page 5
Safety Quick-Guide
Vent exhaust outside and away from any building air intakes.
Use unit outside in open, well ventilated areas.
Engine exhaust gases can kill.
Keep hands, hair, loose clothing, and tools away from moving parts such as fans, belts, and
rotors. Keep all doors, panels, and guards closed and secured.
Moving parts can cause injury.
Sparks can cause battery gases to explode.
Do not smoke and keep matches and flames away from battery.
Wear a face shield or safety glasses when working near or on a battery.
Battery explosion can blind.
Do not spill acid.
Wear rubber gloves and a face shield or safety glasses when working on a battery.
Battery acid can burn skin and eyes.
Check coolant level when engine is cold to avoid scalding.
If the engine is warm and checking is needed, wear safety glasses and gloves and put a rag
over radiator cap. Turn cap slightly and let pressure escape slowly before completely
removing cap.
Steam and hot coolant can burn.

Page 6
Safety Quick-Guide
Use approved engine exhaust spark arrestor in required areas — see applicable codes.
Keep exhaust and exhaust pipes away from flammables.
Do not locate unit near flammables.
Exhaust sparks can cause fire.
4. Plasma Arc Cutting Hazards
Do not cut on drums, tanks, or any closed containers unless a
qualified person has tested it and declared it or prepared it to be
safe (see AWS F4.1 listed in Section 7).
Do not cut near flammable material. Move flammables at least 35
feet (11 meters) away or protect them with flame-proof covers (see
NFPA 51B listed in Section 7).
Cutting sparks can cause fires. Have a fire extinguisher nearby,
and have a trained fire watch ready to use it.
Cutting sparks can cause fire or explosion.
Turn off power before disassembling torch.
Do not grip material near cutting path.
Do not touch hot parts bare-handed.
Plasma arc can cause injury and burns.

Page 7
Safety Quick-Guide
Disconnect input plug or power before working on machine.
Do not make input connections if color blind.
Frequently inspect input power cord for damage or bare wiring —
repair or replace cord immediately if damaged. Be sure input
ground wire is properly connected to a ground terminal in
disconnect box or receptacle.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Wear dry insulating gloves. Do not wear wet or damaged gloves.
Do not touch live electrical parts.
Protect yourself from electric shock by insulating yourself from
work and ground. Use non-flammable, dry insulating material if
possible, or use dry rubber mats, dry wood or plywood, or other dry
insulating material big enough to cover your full area of contact
with the work or ground, and watch for fire.
Electric shock from torch or wiring can kill.
Use a ventilating fan to remove fumes from the breathing zone and
cutting area.
If adequacy of ventilation or exhaust is uncertain, have your
exposure measured and compared to the Threshold Limit Values
(TLV) in the Material Safety Data Sheet (MSDS).
Keep your head out of the fumes. Do not breathe the fumes. Use
enough ventilation, exhaust at the arc, or both, to keep fumes and
gases from your breathing zone and the general area.
Read Material Safety Data Sheets (MSDSs) for metals, consum-
ables, and coatings.
Use enough forced ventilation or local exhaust (forced suction) at
the arc to remove the fumes from your breathing area.
Breathing cutting fumes can be hazardous to
your health.

Page 8
Safety Quick-Guide
Wear complete body protection. Wear oil-free protective clothing
such as leather gloves, heavy shirt, cuffless pants, and high boots.
Wear welders cap and safety glasses with side shields. Use ear
protection when cutting out of position or in confined spaces.
Button shirt collar.
Use welding helmet or face shield with correct shade of filter (see
Section 8 to choose the correct shade).
Arc rays can burn eyes and skin.
5. Trailer Safety
Overloading can cause serious injury or equipment damage.
Know the capacity of the trailer.
Do not overload the trailer.
Select a proper towing vehicle.
GVWR − Gross Vehicle Weight Rating
(Maximum Total Trailer Weight Includ-
ing Its Load)
GAWR − Gross Axle Weight Rating
VIN NO−Vehicle Identification Number
Rating
Plate

Page 9
Safety Quick-Guide
Install generator according to Own
-
er’s Manual with engine end toward
hitch end of trailer.
Ground generator frame to traile
r
frame — see Owner’s Manual.
Distribute weight so that traile
r
tongue weight is approximately 10%
of the gross trailer weight (GTW).
Do not let tongue weight exceed
coupler and hitch rating.
Trailer
1
2
3
Gross Vehicle Gross Trailer Maximum
Up to 2000
(Up to 910)
2000 to 3500
(910 to 1590)
3500 to 5000
(1590 to 2270)
1000 (455)
2000 (910)
2000 (910)
3500 (1590)
3500 (1590)
100 (45)
200 (90)
200 (90)
350 (158)
350 (158)
Pipe
Bathroom
Scale
Approximately
10% Of GTW
Tongue − Level
Board
Class1
1Information From SAE J684 May 1987
2Gross Trailer Weight (Actual Loaded Weight)
310% Of GTW Recommended
And
Coupler Weight Rating GVWR
lb (kg) Weight GTW2 lb (kg) Tongue Weight3 lb (kg)
Incorrect tongue weight can cause fishtailing and loss of control o
f
towing vehicle resulting in serious injury and equipment damage
.
Always use safety chains when
towing.
Cross safety chains under coupling to
prevent tongue from dropping to
ground.
Allow only enough slack for tight
turns.
Bottom View
Side View
Safety chains can prevent runaway trailer in case hitch/coupler
fails.
Make sure hitch and ball are properly
sized, match each other, and are
fully engaged.
On optional ball couplers, always
insert hitch safety pin before towing.
Clevis
Lunette
Eye
Ball
Trailer
Tongue
Couplers
Safety Pin
Incorrect size or rating of hitch can cause trailer to break loose
from towing vehicle.