Miller HJ134589 Owner'S Manual Download | Manualshive

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Summary of Contents for HJ134589

Page 1: ... 1978 FORM OM 457C MODEL Trailblazer 22G OWNERS MANUAL ITIIIIER MILLER ELECTRIC MFG CO 718 S BOUNDS ST P O Box 1079 APPLETON WI 54912 USA Effective With Serial No HJ134589 NWSA CODE NO 4579 PRINTED IN U S A ...

Page 2: ...ators where failure does not result BUT FOR THIS PROVISION MIGHT ARISE BY from defect in workmanship or materiat IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY In the case of Millers breach of warranty or any other IMPLIED WARRANTY OF MERCHANTABILITY OR OF duty with respect to the quality of any goods the exclusive remedies therefor shall be at Millers option 1 rep...

Page 3: ...pped Ungrounded AMENDMENT TO SECTION 5 FUNCTION OF GENERATOR CONTROLS Amend Sections 5 1 and 5 9 Add the following CAUTION block at the beginning of the section TC 000 680 B Amend Figure 3 3 Power Plant Connections Figure 3 3 Power Plant Connections CAUTION _______ The auxiliary power capability of this welding generator is primarily intended for use with portable cord connected accessory equipmen...

Page 4: ...st move freely on the float axle This engine is equipped with a Teledyne Walbro carburetor To ensure correct fuel level in the float chamber check distance dimension A Figure 9 1 from top of float to machined surface of throttle body no gasket with throttle body inverted This dimension should be 1 1 16 inches plus or minus 020 inch To increase or decrease distance from the top of the float body to...

Page 5: ...e IDLE CONTROL switch in the AUTOMA TIC IDLE position To obtain this condition it may be necessary to adjust screw 16 Check by manually pivoting the vacuum motor arm 17 until screw 16 butts against the mounting plate 4 Place the IDLE CONTROL switch in the AUTOMATIC IDLE position Operation of the idling device is automatic when the IDLE CONTROL switch is in the AUTOMATIC IDLE position When the engi...

Page 6: ...e the main adjustment screw 21 clockwise until the engine begins to falter and lose RPM Rotate the main adjustment screw 21 counterclockwise until the engine operates smoothly then continue counterclockwise rotation of 1 4 turn Rotating the screw 21 clockwise restricts the fuel flow making the air fuel mixture leaner Rotating the screw 21 counterclockwise admits more fuel making the air fuel mixtu...

Page 7: ...N ORDERING REPLACEMENT PARTS OM 457C Page E Description Page 4 Page 5 97 TAC HM 032 936 032 936 039 269 100 146 S2 5 VALVE shut off w strainer fuel GUARD fan CATCH door REACTOR SUPPRESSOR 0 75 uf 65 volts ac Eff with S N HK311202 METER dia mkg changed FUSE BOX Eff with S N HJ211479 BLANK snap in 7 8 Eff with S N HJ21 1479 COVER junction box Eff with S N HJ21 1479 CLAMP steel cushion 3 4 dia x 13 6...

Page 8: ...p ...

Page 9: ...ction General Precautions Arc Welding Standards Booklet Index 1 3 4 5 5 5 5 3 5 120 240 Volts AC Terminals SECTION 4 ENGINE PREPARATION Lubrication Coolant System Preparing New Battery For Service Air Cleaner Fuel SECTION 5 FUNCTION OF GENERATOR CONTROLS 120 Volts AC Receptacle Range Switch Fine Amperage Control Remote Amperage Control Volt Ampere Curves Duty Cycle Polarity Switch Meters 240 Volts...

Page 10: ...overnor Service 15 9 4 Carburetor Float Setting 15 9 5 Vacuum Circuit Air Filter 15 9 6 Idle Control Time Delay Adjustment 15 9 7 Carburetor Air Temperature Selector 15 9 8 Air Cleaner Service 16 9 9 Idle Control Governor Linkage Adjustment 17 9 10 High Altitude Carburetor Modification 18 9 11 Key Type Ignition Switch Lubrication 18 9 12 Spark Arrestor 18 SECTION 10 TROUBLESHOOTING PARTS LIST ...

Page 11: ...es Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface the area is well ventilated or the operator wears an air suppied respirator Work in a confined ...

Page 12: ... Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 130F Cool with water spray where such exposure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cylinders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by ha...

Page 13: ...ing a separate room or enclosed bay is best In open areas surround the operation with low reflective non cornbustible screens or panels Allow for free air circulation particularly as floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that s...

Page 14: ...rom welding power source and pull all 115 volts line cord plu Do not open power circuit or change polarity while welding If in an emergency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and dis connect all power to equipment Power disconnect switch must be available near the welding power source 1 4 STANDARDS BOOKLET INDE...

Page 15: ...ation concerning this equipment it is essential that Model Description and or Stock Number and Serial or Style Numbers of the equipment be supplied 2 3 DESCRIPTION This welding generator is driven by a gasoline engine The Unit will produce a dc output for Shielded Metal Arc SMAW Welding when used as a welding generator or an ac output of 7 5 kva at 120 240 volts when used as a power generator A du...

Page 16: ...rmit easy removal of the outer enclosure for maintenance functions Do not place any filtering device over the intake air passages of the welding generator as this would restrict the volume of intake air and thereby subject the internal components to an overheating condition and subsequent failure Warranty is void if any type of filtering device is used On most welding generators a lifting device i...

Page 17: ...ATOR MUST BE USED WHILE MOST WELDING GENERATORS HAVE AN OPEN CIRCUIT VOLTAGE OF LESS THAN 100 VOLTS SOME WELDING GENERATORS OF SPECIAL DESIGN MAY HAVE HIGHER OPEN CIRCUIT VOLTAGE 3 3 EQUIPMENT GROUNDING TERMINAL Figure 3 2 Normally engine driven Welding generators do not require grounding However since this unit has auxiliary power plant capability grounding of the frame and case may be required A...

Page 18: ...he engine with a defective thermostat or without one If this is done the engine will run cold and develop excess carbon accumulation and the oil will become contaminated with excessive sludge and dirt I The radiator for this engine is equipped with a pressurized cap which is rated at 7 psi If this cap is ever replaced ensure that the replacement cap has a rating of 7 psi on a hou Id be ax ercised ...

Page 19: ...ne _j IC 0 U J 1 0 2 5 4 0 6 0 9 0 12 0 POWER KVA AT 100 DUTY CYCLE I AVAILAILI Figure 4 2 Fuel Consumption Chart 1IIC UiR Do not attempt to fill the fuel tank with the engine running Do not fill the fuel tank completely as cold fuel will expand when exposed to outside temperature in a warm climate or to engine heat If the thnk is too full it will overflow causing a potential fire hazard Never all...

Page 20: ...mote control of the amperage is desired it is essential that the REMOTE AMPERAGE CONTROL switch be placed in the REMOTE position Likewise if a Remote Amperage Control is not to be utilized the switch must be in the STANDARD position When in the STANDARD position only the FINE AMPERAGE control on the front panel will control the amperage When a Remote Amperage Control is being used the remote contr...

Page 21: ...lding process These meters are internally connected to the welding generator output ter minals The voltmeter will indicate the voltage at the weld output terminals not the actual voltage at the welding arc due to cable resistance The ammeter will indicate the current output of the welding generator 5 9 240 VOLTS AC DUPLEX RECEPTALCE Optional Figure 5 1 This welding generator is equipped with a vol...

Page 22: ...TO MATIC IDLE LOCK OUT The AUTOMATIC IDLE posi tion allows the engine to idle until an arc is struck The LOCK OUT position of the switch is used whenever it is necessary or desirable to operate the engine at constant weld rpm 1800 The LOCK OUT position must be used when 120 volts ac power is required from the 120 VOLTS AC receptacle or when the 7 5 kva power plant is being utilized The IDLE CONTRO...

Page 23: ...may be adjusted while welding Always ensure that the starter pinion and flywheel h e stopped rotating before re engaging the starter motor otherwise the ring or pinion may be damaged 6 When the engine Starts release the START push button As the engine warms up slowly push the CHOKE in 7 4 ENGINE SHUT DOWN 1 Remove all weld and power loads from the generator 2 Allow the engine to idle for a few min...

Page 24: ...rom the radiator neck When removing the cap it is recommended that a glove or rag be used to protect the operators hand from possible exposure to extremely hot coolant mixd4erenandso ls GeneraIly motor oils fall into two categories phosphate base and sulphonate base The phosphate base oils are acidic the sulphonates are alkaline Although both bases produce good oils mixing the two bases produces a...

Page 25: ...ease distance from the top of the float bodies to the gasket face use a long nose pliers and bend the float lever at a point close to the float body The edge of the float should be kept parallel with the gasket 9 5 VACUUM CIRCUIT AIR FILTER Figure 9 3 In order to provide clean air for the vacuum circuit a brass fitting type air cleaner is provided on the underside of the idle control valve See Fig...

Page 26: ...e 9 6 It is recommended that a spare element always be kept on hand for replacement New elements are available from your distributor 5 Shake out excess water from the element and allow to air dry Compressed air not to ex ceed 100 lbs of pressure can clean the element In sert nozzle inside the ele ment and blow out dust Clean dust from the out side of the element by holding the nozzle at least 6 in...

Page 27: ...er repeat Step 2 A Position the arm 8 laterally so that the carbur etor linkage socket 4 does not touch the throttle stop plate 2 throughout its entire travel B Position the arm 8 radially so that the arm 8 travels an equal distance to either side of an imaginary center line drawn perpendicular to the center of the throttle shaft 9 Tighten the alignment screw 7 and recheck the ad justments made in...

Page 28: ...esired governor sensitivity Readjust the governor sensitivity by repeating Step 11 NOTE Whenever the governor sensitivity Step 11 is adjust ed the governor speed Step 10 must be readjusted Whenever the governor speed Step 10 is adjusted the governor sensitivity Step 11 may need readjustment 9 10 HIGH ALTITUDE CARBURETOR MODIFICATION Optional Figure 9 8 The Zenith carburetor may be equipped with an...

Page 29: ...a screwdriver or similar tool 3 Start the engine and run it at idle rpm to blow collected particles out the cleanout hole If particles are slow to discharge momentarily cover the end of the exhaust stack 4 Stop the engine Replace and secure the cleanout plug TC 003 226 Figure 9 8 High Altitude Carburetor Adjustment SECTION 10 TROUBLESHOOTING CAUTION Hazardous voltages are present on t ternalcir cu...

Page 30: ... Defective 120 volts ac winding Have 120 volts ac winding replaced at authorized service station No weld or ac power output Defective brushes Replace brushes Defective rotor Have rotor replaced at authorized service station Erratic weld current Damp or defective electrodes Use new dry electrodes Loose or dirty connections Check Connections both inside and outside of welding generator Check leads a...

Page 31: ...UST RE INSTALLED RETWEEN ENGINE ERAME AND WELDER FRAME I3 ft45 ThERR4 30t j3 t50 5333 JR 127 PIC R 23 2D LOW REAR DIEW r CI CAUTION p REFER TO OWNERS I I ATTEMPTING UOLTDGE I C0 P4RU lh I I OPTIONDL EIT I INCLUDING 2ADVOLT I RECEPTACLE I LP GAS AlT AND TOTAL TIME METER Figure 1O 1 Circuit Diagram OM 457 Page 21 ...

Page 32: ......

Page 33: ...April 1978 FORM OM 457C PARTS LIST Effective With Serial No HJ134589 ...

Page 34: ...Figure A Main Assembly 54 55 56 57 58 OM 457 Page 1 ...

Page 35: ...0 11 0 03 C CD 11 a1_ w I 0 a 0 0 9 CD ...

Page 36: ... 027 529 PIN cotter 1 4 x 3 1 2 6 27 010 875 CLAMP muffler 2 inch dia 1 28 028262 MUFFLER exhaust 1 29 015 700 BRACKET ASSEMBLY mounting muffler consisting of 1 30 010 955 WASHER flat steel 13 32 ID x 2 OD x 1 8 2 31 073 355 SPR ING compression 1 32 027564 SPACER anti noise 2 33 053724 GUARD fan 2 34 017 363 HOSE i adiator upper 1 35 028 404 RADIATOR consisting of 1 36 605 982 CAP radiator 7 lb pr...

Page 37: ...025 932 SUPPRESSOR 0 75 uf 10 ohm w leads 1 81 028 218 FRAME mounting reactor stabilizer 1 82 Z2 031 220 STABILIZER 1 83 603 125 STRIP cotton 1 8 x 4 4 ft reqd order by ft 4 ft 004 426 KIT label includes all labels 1 Parts for Optional Equipment A2 025 103 METER amp dc 5OMV 0 600 scale 1 RC2 604 103 RECEPTACLE straight duplex grounded 2P3W 15 amp 250 volts 1 025 234 CAP straight grounded 2P3W used...

Page 38: ...O PROVIDE STOCK MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS 97 98 99 100 Figure B Generator Assembly 2 TO 006 562 Description Quantity BRACKET mtg tachometer BRACKET mtg tachometer to engine METER hour 4 40 volts METER volts dc 0 100 scale MUFFLER exhaust low noise JET carburetor high altitude CLAMP muffler 2 inch dia PIPE black 1 1 2 x 4 3 4 Page 5 ...

Page 39: ...or details BE SURE TO PROVIDE STOCK MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS ENDBELL DIODE ASSEMBLY reverse polarity consisting of INSULATOR DIODE 275 amp 250 volts reverse polarity INSULATOR CHANNE L neoprene 1 4 inch x 11 1 2 long BOX fuse holder FUSE cartridge 45 amp 250 volts HOLDER fuse cartridge 60 amp 250 volts BUSHING snap 5 8 ID 7 8 mounting hole STATOR BAFFLE air GUARD ge...

Page 40: ...164 Figure Cl Figure C Panel Front Upper With Components 146 TC 006 071 A Page 7 ...

Page 41: ... 146 S2 5 053 359 SWITCH toggle SPST 20 amp 125 volts 2 147 RC3 032 897 RECEPTACLE twistlock grounded 2P3W 148 RC1 604 176 RECEPTACLE straight duplex grounded 2P3W 15 amp 125 volts 1 149 Si 005 372 S NITCH ignition key type w o start 1 150 P81 011 767 SWITCH push button starter 151 CR1 034876 RELAY reed 152 039 047 TERMINAL power output red consisting of 153 601 976 SCREW cap steel hex hd 1 2 13 x...

Page 42: ...412 011 490 011 025 011 010 011 009 010 200 010 202 010 201 011 007 011 018 011 489 011 018 010 200 010 202 010 201 011 095 011 019 011 012 011 013 SPRING pressure CONTACT switch copper CONTACT switch bronze SPACER contact 024 thick SPACER contact 1 8 thick SPACER contact 1 16 thick SPRING pressure CONTACT stationary CONTACT ASSEMBLY stationary consisting of CONTACT stationary SPACER contact 024 t...

Page 43: ...VE shut oft needle BUSHING brass pipe reducer 1 4 MPT 1 8 FPT TUBING copper 3 16 OD x 030 waIl x 13 1 2 CHAMBER vacuum HOSE neoprene 7 64 ID x 4 TEE brass 1 8 x 1 8 RECTIFIER selenium TUBING copper 1 4 OD x 030 waIl x 1 VALVE 12 volts dc 2 way 1 4 IPS port 1 8 orifice BREATHER brass pipe vent RIVET steel round head 1 4 x 2 BRACKET mounting chamber vacuum GROMMET rubber 5 16 ID x 1 2 hole 3 16 groo...

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