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.

Page 10
Safety Quick-Guide
1. Chock in direction of grade.
2. Position chock snugly behind tire.
3. Place chock square to the tire.
4. Tap chock into place.
5. For added protection, chock both sides
of tire.
Wheels must be chocked when trailer is uncoupled from vehicle.
Be sure vehicle and trailer light connec-
tors match and are securely pushed
together.
Check all lights for proper operation
before using the trailer.
Check condition of wiring harness
leads, plugs, bulbs, and connections
regularly. Repair or replace damaged
bulbs, parts, or wires.
Incorrectly working lights can cause accidents.
Tail, Stop, and
Turn Lights
Side Marker Lights
When trailer is uncoupled from towing
vehicle, use jack on front and blocks
under rear to prevent tilting.
Use proper blocks that are large
enough and able to support the neces-
sary weight.
Always chock the wheels when un-
coupled.
Unexpected tilting of trailer can cause injury and damage.
Periodically double-check all nuts and
bolts for tightness and condition.
If necessary, always replace any
fastener with one of equal size, grade,
and type.
Be sure the grade marks on replace-
ment fastener match the original bolt.
The manufacture’s identification mark
is not critical and does not matter for the
replacement fastener.
Loose or incorrect hardware and fasteners can cause injury and
damage.
Grade Marks
Manufacturer’s
Identification Mark

Page 11
Safety Quick-Guide
6. Special Situations & Equipment
Confined spaces are areas which lack room for full movement and often lack ventilation, such
as storage tanks, vats, tunnels, boilers, pipes, hold of a ship, corners of a room, near a ceiling
or floor corner, or in a pit. Gases can collect and form dangerous concentrations.
Always open all covers, remove any hazardous or toxic materials, provide forced ventilation,
and provide a means to turn off power and gas from the inside.
Never work alone — have constant communication with someone outside who can quickly
turn off power and gas, is trained in rescue procedures, and is able to pull you out in case
of emergency.
Do not use AC weld output in confined spaces.
Insulate yourself from work and ground using 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.
Always check and monitor the air quality in the space. Welding or cutting fumes and gases
can displace air and lower the oxygen level — use ventilation and, if needed, an air-supplied
respirator. Be sure the breathing air is safe.
Always remember: All normal arc welding and cutting hazards are amplified in confined
spaces (see ANSI Z49.1 listed in Section 7).
Confined spaces can be hazardous.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process and may be part of the cutting
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open
flames, sparks, and arcs.
Install cylinders in an upright position by securing them to a stationary support or cylinder rack
to prevent falling or tipping.
Keep protective cap in place over valve except when cylinder is in use or connected for use.
Cylinders can be heavy — use lifting device and proper methods to prevent back injury.
Read and follow instructions on compressed gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards (see Section 7).
Cylinders can explode if damaged.
Pacemaker wearers keep away from arc welding and cutting operations and equipment.
Wearers should consult their doctor before going near arc welding, gouging, arc cutting, or
spot welding operations.
Magnetic fields can affect pacemakers.

Page 12
Safety Quick-Guide
Do not touch hot welded or cut parts with bare hand. If handling is needed, use proper tools
and/or wear heavy, insulated welding gloves to prevent burns.
Allow cooling period before handling parts or working on gun or torch.
Hot parts can cause severe burns.
7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: [phone], website:
www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and
Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126 (phone: [phone], website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, web-
site: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed
Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102
(phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−interna-
tional.org).
Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute, 11 West 42nd Street, New York, NY
10036−8002 (phone: 212−642−4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard
51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy,
MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of
Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S.
Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh,
PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220,
website: www.osha.gov).
Booklet, TLV’s, Threshold Limit Values0,from American Conference of Governmental
Industrial Hygienists (ACGIH), 1330 Kemper Meadow Drive, Suite 600, Cincinnati, OH
45240-1634 (phone: 513−742−2020, website: www.acgih.org).

Page 13
Safety Quick-Guide
8. Lens Shade Selector Guide
Operation/Process Electrode Size
in. (mm) Arc Current (Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Shielded metal arc
welding (SMAW) Less than 3/32 (2.5) 3/32−5/32 (2.5−4)
5/32−1/4 (4−6.4)
More than 1/4 (6.4)
Less than 60
60−160
160−250
250−550
7
8
10
11
—
10
12
14
Gas metal arc
welding (GMAW) and
flux cored arc
welding (FCAW)
Less than 60
60−160
160−250
250−550
7
10
10
10
—
11
12
14
Gas tungsten arc
welding (GTAW) Less than 50 50−150
150−500
8
8
10
10
12
14
Air carbon arc cutting
(CAC−A) (Light) (Heavy) Less than 500 500−1000 10 11 12 14
Plasma arc welding
(PAW) Less than 20 20−100
100−400
400−800
6
8
10
11
6 to 8
10
12
14
Plasma arc cutting
(PAC) Less than 20 20−40
40−60
60−80
80−300
300−400
400−800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Torch brazing (TB) — — 3 or 4
Torch soldering (TS) — — 2
Carbon arc welding
(CAW) — — 14
Plate thickness
in. mm
Oxyfuel gas welding
(OFW)
Light
Medium
Heavy
Under 1/8
1/8 to 1/2
Over 1/2
Under 3.2
3.2 to 12.7
Over 12.7
4 or 5
5 or 6
6 or 8
Oxygen Cutting (OC)
Light
Medium
Heavy
Under 1
1 to 6
Over 6
Under 25
25 to 150
Over 150
3 or 4
4 or 5
5 or 6
* As a rule of thumb, start with a shade that is too dark to see the weld or cut zone. Then go to a lighter shade
which gives sufficient view of the weld or cut zone without going below the minimum. In oxyfuel gas welding,
cutting, or brazing where the torch produces a high yellow light, it is desirable to usea filter lens that absorbs
the yellow or sodium line in the visible light of the (spectrum) operation.
Guide adapted from ANSI Z49.1, 1999.
Low Current Plasma arc cutting data (0−80 Amperes) supplied by Miller Electric Mfg. Co.

Page 14
Safety Quick-Guide
9. Weld Cable Selector Guide*
YTurn Off power before connecting
to weld output terminals.
YDo not use worn, damaged, under-
sized, or poorly spliced cables. Electrode Work
Weld Cable Size** And Total Cable (Copper) Length
In Weld Circuit Not Exceeding***
100 ft (30 m) Or Less 150 ft
(45 m) 200 ft (60 m)
Welding
Amperes 10 − 60% Duty Cycle 60 − 100% Duty Cycle 10 − 100% Duty Cycle
100 4 4 4 3
150 3 3 2 1
200 3 2 1 1/0
250 2 1 1/0 2/0
300 1 1/0 2/0 3/0
350 1/0 2/0 3/0 4/0
400 1/0 2/0 3/0 4/0
500 2/0 3/0 4/0 2 ea. 2/0
600 3/0 4/0 2 ea. 2/0 2 ea. 3/0
700 4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0
800 4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0
900 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0
1000 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0
1250 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 4 ea. 3/0
*This chart is a general guideline and may not suit all applications. If cable overheating occurs
(normally you can smell it), 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. Contact your distributor for the mm2equivalent weld cable sizes.
***For distances longer than those shown in this Guide, call a factory applications
representative at 920-735-4505.

M199776B 8/03 2003 Miller Electric Mfg. Co. PRINTED IN USA
For additional FREE copies, call
920−735−4356, or fax 920−735−4011.
Miller Electric Mfg. Co.
1635 West Spencer St.
An Illinois Tool Works Company
P.O. Box 1079
Appleton, WI 54912-1079 USA
Hobart Welding Products
An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA