Instruction/ maintenance manual of the product Trailblazer DC Miller Electric
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Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) Welding Flux Cored (FCAW) Engine Driven Welding Generator (AC Available On AC/DC Models Only) OM-4407 203 236U May 2004 T railblazer 301 G T railblazer DC V isit our website at www.
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 catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label (Robin EH64-Powered Units) 29 . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4407 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-4407 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
OM-4407 Page 3 STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).
OM-4407 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F .
OM-4407 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03 A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
OM-4407 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué.
OM-4407 Page 7 L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE. T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.
OM-4407 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
OM-4407 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil Engine Choke.
OM-4407 Page 10 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode Rated W elding Output Maximum Open-Circuit V oltage Amperage Range In CC Mode V oltage Range In CV Mode Generator Power Rating Fuel Capacity Engine CC/DC 280 A, 25 V , 100% Duty Cycle 80 20 − 300 A Continuous: 9.
OM-4407 Page 1 1 IDLE − KOHLER AND ROBIN ROBIN 4-3. Fuel Consumption While W elding 05 0 100 150 200 250 300 DC WELD AMPERES A T 100% DUTY CYCLE KOHLER 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 US GAL/HR. 0.00 0.95 1.89 2.84 3.79 4.73 5.68 6.62 7.
OM-4407 Page 12 Ref. 204 922 The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 4-5. Generator Power Curve 0 50 100 150 200 250 300 0 1 02 03 0 4 05 06 07 08 0 9 0 AC AMPERES AC VOL TS 216 10,000 watts Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.
OM-4407 Page 13 204 923 / 204 928 / 204 935 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. AC output is not available on all models.
OM-4407 Page 14 204 934 / 204 930 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. AC output is not available on all models.
OM-4407 Page 15 SECTION 5 − INST ALLA TION install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Do not weld on base. W elding on base can cause fuel tank fire or explosion.
OM-4407 Page 16 5-2. Engine Prestart Checks (Robin EH64-Powered Units) 803 098 / 800 392-J Full Full Gasoline Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual.
OM-4407 Page 17 5-3. Engine Prestart Checks (Kohler-Powered Units) 801 221 / 802 849-A Full Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in engine manual. This unit has a low oil pressure shutdown switch.
OM-4407 Page 18 5-4. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-4407 Page 19 5-5. Connecting The Battery Ref. 800 394-C / Ref. 206 422 / Ref. S-0756-D + − 3/8, 1/2 in Connect negative ( − ) cable last. T ools Needed: 5-6. Installing Exhaust Pipe 801 681 / Ref. 206 422 Stop engine and let cool. Engine backfire can cause se- vere burns or other injuries.
OM-4407 Page 20 5-7. Connecting T o Weld Output T erminals Stop engine. Do not connect to CC and CV terminals at the same time. AC/DC Models: 1 W ork Weld Output T erminal 2 Stick/TIG (CC) W e.
OM-4407 Page 21 5-8. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals Stop engine before connecting t o weld out- put terminals.
OM-4407 Page 22 5-10. Adjusting Wire (MIG) Weld Puddle Consistency 803 099 3/8, 7/16 in T ools Needed: 1 3 2 Stop engine and let cool. Stabilizer DC-Z is factory connected to suit most Wire (MIG) welding applications. T o change Wire (MIG) weld puddle consis- tency , proceed as follows: Remove cover and right side panel.
OM-4407 Page 23 SECTION 6 − OPERA TING WELDING GENERA T OR 6-1. Front Panel Controls 1 Process/Contactor Switch See Section 6-2 for Process/Contactor switch information. 2 V oltage/Amperage Adjust Switch And Remote Receptacle Use switch to select front panel or remote voltage/amperage control.
OM-4407 Page 24 6-2. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch W eld output terminals are ener- gized when Process/Contactor switch i s i n a n Electrode Hot posi- tion and the engine is running.
OM-4407 Page 25 6-3. Remote Amperage/V oltage Control 1 Remote Receptacle RC4 Connect optional remote control to RC4 (see Section 5-9). 2 Remote Hand Control (Optional) 3 Remote Foot Control (Optional.
OM-4407 Page 26 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers Ref. 206 422 1 2 5 3 If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases as weld current increases.
OM-4407 Page 27 7-2. Optional Generator Power Receptacles If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases as weld current increases. Combined output of all receptacles limited to 8 kV A/kW rating of the generator .
OM-4407 Page 28 7-3. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) plug1 1 1/03 − 120 813-D The plug can be wired for a 240 V , 2-wire load or a 120/240V , 3-wire load.
OM-4407 Page 29 SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) 8-1. Maintenance Label (Robin EH64-Powered Units).
OM-4407 Page 30 8-2. Routine Maintenance (Robin EH64-Powered Units) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period.
OM-4407 Page 31 Every 200 h Replace fuel filter . See Section 8-6 . Change oil filter . See Section 8-6 and maintenance label. Check spark plugs. Replace unreadable labels. Every 500 h Repair or replace cracked cables. Service welding generator brushes and slip rings.
OM-4407 Page 32 8-3. Servicing Air Cleaner (Robin EH64-Powered Units) aircleaner5 1/97 − 803 070 / Ref. 200 017 / S-0759 Stop engine. Do not run engine without air cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution.
OM-4407 Page 33 Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote receptacle RC4.
OM-4407 Page 34 8-6. Changing Engine Oil, Oil Filter , and Fuel Filter (Robin EH64-Powered Units) 803 098 / S-0842 Stop engine and let cool. 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Close valve and valve cap before adding oil and running engine.
OM-4407 Page 35 8-7. Adjusting Engine Speed (Robin EH64-Powered Units) 803 098 After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Remove wrapper to access speed adjustments.
OM-4407 Page 36 SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units) Recycle engine fluids. Stop engine before maintaining. Se e also Engine Manual and Maintenance Label for im- portant start-up, service, and storage information.
OM-4407 Page 37 9-2. Maintenance Label (Kohler-Powered Units) Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period.
OM-4407 Page 38 9-3. Servicing Air Cleaner (Kohler-Powered Units) aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759 Stop engine. Do not run engine without air cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution.
OM-4407 Page 39 9-5. Changing Engine Oil, Oil Filter , And Fuel Filter (Kohler-Powered Units) 802 849-A / S-0842 Stop engine and let cool. 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter accord- ing to engine manual. Close valve and valve cap before adding oil and run- ning engine.
OM-4407 Page 40 9-6. Adjusting Engine Speed (Kohler-Powered Units) 802 849-A / 801 209-A After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. T u rn A/V control to 10.
OM-4407 Page 41 Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote receptacle RC4.
OM-4407 Page 42 SECTION 10 − TROUBLESHOOTING 10-1. Welding T roubleshooting T rouble Remedy No weld output. Check control settings. Check weld connections.
OM-4407 Page 43 T rouble Remedy Lack of high frequency; difficulty in establishing Gas Tungsten Arc W eld- ing arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.
OM-4407 Page 44 T rouble Remedy Engine does not start. Check fuel level (see Section 5-2 or 5-3). Check battery and replace if necessary . Check engine charging system according to engine manual.
OM-4407 Page 45 Notes W or k l i k e a P r o! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual ..
OM-4407 Page 46 SECTION 1 1 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For W elding Generator Models With AC/DC Output.
OM-4407 Page 47 209 625-C.
OM-4407 Page 48 Figure 1 1-2. Circuit Diagram For Welding Generator Models With DC Output Only (Kohler Only).
OM-4407 Page 49 209 620-B.
OM-4407 Page 50 SECTION 12 − GENERA T OR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref.
OM-4407 Page 51 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-4407 Page 52 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 21.
OM-4407 Page 53 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-4407 Page 54 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
OM-4407 Page 55 12-10. T ypical Connections T o Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’ s Manual and national, state, and local codes.
OM-4407 Page 56 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-4407 Page 57 Notes.
OM-4407 Page 58 SECTION 13 − P ARTS LIST 802 951 Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 11 14 16 17 10 28 27 26 25 29 30 31 34 36 18 37 40 56 57 − Fig.13-2 45 32 59 58 35 54 55 50 33 20 15 19 − Fig.13-3 22 21 23 38 41 42 44 43 46 47 48 49 51 52 53 24 60 Figure 13-1.
OM-4407 Page 59 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 182367 Panel, Side Rh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4407 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 25 168385 Label, W arning Battery Explosion Can Blind 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 +201 174 Door , Access Battery 1 .
OM-4407 Page 61 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 206537 Harness, W rg Ignition (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4407 Page 62 802 952 Hardware is common and not available unless listed. 1 5 6 7 10 8 11 12 13 14 18 19 20 21 22 24 25 27 28 29 30 31 33 36 15 26 3 2 23 32 4 16 17 34 35 9 Figure 13-2.
OM-4407 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Panel, Front w/Components (Figure 13-1 Item 57) Quantity 1 206854 Panel, Front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4407 Page 64 Description Part No. Item No. Figure 13-3. Generator (Figure 13-1 Item 19) Quantity 1 +206 406 Stator , Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 3/04 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mf g. Co. An Illinois T ool Wor ks Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − .
An important point after buying a device Miller Electric Trailblazer DC (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Trailblazer DC yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Trailblazer DC - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Trailblazer DC you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Trailblazer DC will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Trailblazer DC, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Trailblazer DC.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Trailblazer DC. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Trailblazer DC along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
