Miller Electric Trailblazer Pro 350 D Owner'S Manual Download Page 43 | Manualshive

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OM-4401 Page 39

198 518-A

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Summary of Contents for Trailblazer Pro 350 D

Page 1: ...ing MIG GMAW Welding Engine Driven Welding Generator OM 4401 198 521M May 2002 Trailblazer Pro 350 Flux Cored FCAW Welding Visit our website at www MillerWelds com Air Plasma Cutting and Gouging with...

Page 2: ...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 will help you protect yourself again...

Page 3: ...Controls See Section 5 2 20 5 2 Description Of Controls See Section 5 1 21 5 3 Process Contactor Switch 22 5 4 Operating Unit At Idle Speed 22 5 5 Remote Voltage Amperage Control 23 SECTION 6 OPERATI...

Page 4: ......

Page 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Page 6: ...uch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FI...

Page 7: ...ammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see a...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...oquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du c...

Page 10: ...pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut...

Page 11: ...nir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniqueme...

Page 12: ...W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA P...

Page 13: ...switch while welding 14 Remote 14 Receptacle Work Connection Read Operator s Manual SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Welding Mode Rated Welding Output At Weld Speed R...

Page 14: ...it could tip B 21 1 2 in 546 mm C 1 in 25 mm E F D 15 5 8 in 397 mm F 20 E 26 3 8 in 679 mm F 58 3 4 in 1492 mm 20 20 G 13 32 in 10 mm Dia 20 Weight 1030 lb 467 kg 800 426 Front Panel End 200 334 3 3...

Page 15: ...Cycle at 350 Amperes DC 198 919 100 150 200 250 300 350 400 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE WELD AMPERES DC AC 3 5 AC Generator Power Curve 200 268 The ac power curve shows the gen erator...

Page 16: ...d maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown A CC DC Stick Mode B CC AC Stick Mode 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 300...

Page 17: ...maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown A CC AC TIG Mode B CC DC TIG Mode AC AMPERES AC VOLTS DC AMPERES DC VOLTS 0 10 20 30 40 5...

Page 18: ...ely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes Always ground generator frame to vehicle frame to pre vent electric shock and static e...

Page 19: ...occur during run in period Check oil several times daily during run in Coolant Check coolant level in recovery tank before starting unit the first time Add coolant if coolant is below bottom of radiat...

Page 20: ...t is at bottom of filler neck This en sures all air is purged from the sys tem Reinstall screw and radiator cap Check coolant level in recovery tank see Section 4 2 Engine coolant is a mixture of wate...

Page 21: ...o Weld Output Terminals Do not connect to CC and CV terminals at the same time 1 Work Weld Output Terminal 2 CC Stick TIG Weld Output Terminal 3 CV MIG Weld Output Terminal For MIG welding connect wor...

Page 22: ...s 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...

Page 23: ...OM 4401 Page 19 Notes...

Page 24: ...OM 4401 Page 20 SECTION 5 OPERATING WELDING GENERATOR 5 1 Controls See Section 5 2 203 031 A A Ref 802 579 B 5 6 8 9 11 13 14 7 10 3 2 1 4 15 12...

Page 25: ...ment control is the maximum available at the remote Set V A Adjustment control item12 to max for MIG welding 12 V A Voltage Amperage Adjustment Control With Process Contactor switch in any Stick or TI...

Page 26: ...ith HF Unit Pulsing Device Or Remote Control At Remote 14 Receptacle Remote Stick Stick SMAW With Remote On Off At Remote 14 Receptacle Remote MIG MIG GMAW At Remote 14 Receptacle Electrode Hot MIG MI...

Page 27: ...k In Example Process Stick Using Remote On Off Min 40 A DC Max 180 A DC Adjust Optional Remote Control Set V A Adjust Switch Set Polarity Set V A Control Max 180 A DC Min 40 A DC Set Remote Process Ex...

Page 28: ...and GFCI 5 from overload If CB1 opens the receptacles do not work 5 Circuit Breaker CB3 6 Circuit Breaker CB4 CB3 protects GFCI 4 and CB4 pro tects GFCI 5 from overload If a cir cuit breaker opens th...

Page 29: ...one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Terminal Strip cord jacket back enough to sepa...

Page 30: ...e Section 7 5 FUEL WATER Full Recovery Tank 20 h Check and clean optional spark arrestor screen See Section 7 3 50 h Clean and tighten weld terminals Check fuel lines and connections See Section 7 5 1...

Page 31: ...en in dirty conditions 2000 h Replace radiator coolant and hoses See Section 7 6 Replace fuel lines and clamps See Section 7 5 Stop engine and let cool 1 Cleanout Plug Remove plug and remove any dirt...

Page 32: ...gine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re pl...

Page 33: ...d ding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 4 2 To drain water from fuel system Open secondary fuel filter petcock and drain water into metal contain...

Page 34: ...adiator Cap 3 Radiator Air Bleed Screw Change coolant according to engine manual Add coolant according to Sec tion 4 3 Run engine until engine reaches normal operating temperature Loosen air bleed scr...

Page 35: ...throttle link on new solenoid plungerrod Turn link until the same amount of thread will be visible on plunger rod when the jam nut is tightened Do not tighten jam nut yet Mount solenoid on bracket Mov...

Page 36: ...n nut and turn screw clock wise to increase idle speed Turn screw counterclockwise to de crease idle speed Tighten nut See engine manual for governor sensitivity adjustment Adjusting Weld Power Speed...

Page 37: ...ow plug CB8 protects the engine wiring sys tem from overload If CB8 opens the engine will not crank Check battery starter and engine control switch CB9 protects the engine throttle cir cuit from overl...

Page 38: ...tings Clean and tighten connections both inside and outside unit Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Check an...

Page 39: ...ungsten B Generator Power Trouble Remedy No generator power output weld out put okay Reset circuit breakers CB1 CB3 and or CB4 see Section 6 1 Check fuse F1 and replace if necessary see Section 7 9 Ha...

Page 40: ...l see Section 4 2 Engine will not start if oil pressure is too low Reset circuit breaker CB10 see Section 7 9 Check coolant level and fan belt see Section 4 2 and engine manual Engine will not start i...

Page 41: ...Authorized Service Agent check timer module and current transformer CT1 Reset circuit breaker CB9 see Section 7 9 Engine does not go to high run speed when generator power or large weld load is applie...

Page 42: ...OM 4401 Page 38 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Welding Generator...

Page 43: ...OM 4401 Page 39 198 518 A...

Page 44: ...or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator...

Page 45: ...load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then ad...

Page 46: ...th correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid sw...

Page 47: ...s symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Generat...

Page 48: ...sistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows vol...

Page 49: ...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 M...

Page 50: ...P 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...

Page 51: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 52: ...n 10 11 6 Generator Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generato...

Page 53: ...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 If unit does not have GFCI receptacles use GFC...

Page 54: ...LIST Hardware is common and not available unless listed 9 10 11 7 12 13 15 18 19 20 21 22 28 29 31 32 33 34 36 99 25 26 27 24 2 1 3 4 6 14 16 17 23 FIG 11 2 24 30 35 97 98 100 101 FIG 11 3 102 103 10...

Page 55: ...51 802 625 C 37 FIG 11 4 38 56 17 58 59 60 61 62 64 65 67 68 69 70 71 72 73 74 42 78 80 82 84 88 87 43 44 45 46 47 76 77 79 89 66 41 39 55 53 40 75 57 63 17 85 86 90 91 92 93 94 96 95 54 106 107 81 48...

Page 56: ...ar 1 20 176230 Label Hot Exhaust Parts Do Not Touch 1 21 194320 Latch Lever Flush Trigger 1 22 198154 Door Access Removable 1 22 198870 Door Access Removable Stainless Steel 1 23 Figure 11 2 Mounting...

Page 57: ...d Fan 1 60 191341 Hose Radiator Outlet 1 61 198186 Bracket Mtg Radiator Lh 1 62 197822 Radiator w 14 Cap 3 Row Core 1 125 Inlet Outlet 1 187120 Cap radiator pressure 14 lb 1 63 194578 Baffle Foam Air...

Page 58: ...l Assembly 1 102 090281 Label Caution Do Not Use Ether Use Glow Plugs Et 1 103 168385 Label Warning Battery Explosion Can Blind 1 104 198158 Panel Generator Right 1 104 198874 Panel Generator Right St...

Page 59: ...184 Diode Board 1 8 176199 Clamp Capacitor 1 375 Dia Clip 2 9 PC2 202 013 Circuit Card Assy Field Current Controller consisting of 1 10 176007 Capacitor Elctlt 1200 Uf 300 Vdc Can 1 37 Dia 1 11 T1 035...

Page 60: ...PLG23 066 104 Conn Rect Univ 084 6p S 3row Plug Cable Lkg 1 187654 Seal Wire Univ 12p S 3row 1 27 1T 172661 Block Stud Connection 6 Position 1 28 173734 Link Jumper 2 PLG6 136924 Conn Rect Comm 093 2...

Page 61: ...7 Hardware is common and not available unless listed 802 642 A 34 32 33 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 18 19 12 21 23 24 25 26 27 28 31 35 36 37 38 40 39 28 41 42 43 44 6 29 45 17 22 30 Figure 11...

Page 62: ...96 Circuit Breaker Man Reset 1p 20a 250vac Frict 2 22 CB1 203 026 Circuit Breaker Man Reset 2p 50a 240vac Screw 90 1 23 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 24 601836 Nut 250 20 50hex 19h Brs...

Page 63: ...engine 1 10 187151 Stud Stl 375 16 X 21 500 4 11 010910 Washer Flat 406idx0 812odx 065t Stl Pld Ansi 375 4 12 010909 Nut 375 16 56hex 46h Stl Pld Elastic Stop Nut 4 13 047878 Bar Retaining Brushholder...

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Page 67: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact...

Page 68: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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