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

(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

welding helmet or face shield and at all times in the work area.

Read the equipment Owner’s Manual for more complete safet

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

frame — see Owner’s Manual.

Distribute weight so that traile

tongue weight is approximately 10%

of the gross trailer weight (GTW).

Do not let tongue weight exceed

coupler and hitch rating.

Trailer

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)

3500 (1590)

100 (45)

200 (90)

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

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.

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