Miller TRAILBLAZER 275 DC Page 1 Owner'S Manual Download

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Trailblazer 302

Trailblazer 275 DC

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW)

Engine Driven Welding Generator

(AC Available On AC/DC Models Only)

OM-4426

215 348AD

2012

−

Air Plasma Cutting and Gouging

with Spectrum

Unit

Air Carbon Arc (CAC-A) Cutting

and Gouging

Visit our website at

www.MillerWelds.com

File: Engine Drive

Summary of Contents for TRAILBLAZER 275 DC

Page 1: ...Welding MIG GMAW Welding Flux Cored FCAW Engine Driven Welding Generator AC Available On AC DC Models Only OM 4426 215 348AD 2012 03 Air Plasma Cutting and Gouging with Spectrum Unit Air Carbon Arc C...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...ifications Kohler ECH 730 15 4 3 Dimensions Weights And Operating Angles 16 4 4 Fuel Consumption Curves 17 4 5 Generator Power Curve 18 4 6 Duty Cycle 18 4 7 Stick And MIG Mode Volt Ampere Curves 19 4...

Page 4: ...restor 40 8 5 Servicing Air Cleaner 40 8 6 Changing Engine Oil Oil Filter And Fuel Filter Kohler Powered Units 41 8 7 Changing Engine Oil Oil Filter and Fuel Filter Subaru Powered Units 42 8 8 Adjusti...

Page 5: ...h risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC ma...

Page 6: ...s and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on cont...

Page 7: ...hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scaldin...

Page 8: ...RTS can burn Do not touch hot compressor or air system parts Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clot...

Page 9: ...educe current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use...

Page 10: ...site www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10...

Page 11: ...pareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m...

Page 12: ...casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans...

Page 13: ...des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l a...

Page 14: ...entation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance Ne pas intervenir sur le circuit d air compr...

Page 15: ...er l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et...

Page 16: ...R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s tablir la c...

Page 17: ...n Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And F...

Page 18: ...l Engine Oil Engine Choke Check Valve Clearance Battery Engine Engine Read Operator s Manual A Amperes V Volts MIG GMAW Wire Stick SMAW TIG GTAW Lift Arc TIG Positive Negative Alternating Current AC O...

Page 19: ...ine or Kohler CH 23 Air Cooled Two Cylinder Four Cycle 23 HP Gasoline Engine CV DC 300 A 25 V 100 Duty Cycle 35 13 35 V CC AC 200 A 25 V 60 Duty Cycle 60 35 225 A AC DC Models Only 4 2 Weld Power And...

Page 20: ...be damaged or unit could tip Do not move or operate unit where it could tip Weight 580 lb 263 kg Lifting Eye Weight Rating 1280 lb 580 kg 5 250 6 750 32 750 16 500 2 000 5 750 1 500 105 APPR O XI M A...

Page 21: ...uel per hour Expect about 16 hours of operation with carbureted engine 19 hours with EFI engine 1 00 1 25 1 50 1 75 2 00 2 25 US GAL HR 0 00 0 25 0 50 0 75 1 00 1 50 1 75 2 25 KW AT 100 DUTY CYCLE Idl...

Page 22: ...70 80 90 100 AC AMPERES AT 240 V AC VOLTS 10 EFI Engine Carb Engine 0 20 40 60 80 100 120 140 160 180 200 AC AMPERES AT 120 V 0 25 50 75 100 125 150 Duty cycle is the percentage of 10 minutes that uni...

Page 23: ...e curves shown A CC DC Stick Mode B CV DC MIG Mode 4 7 Stick And MIG Mode Volt Ampere Curves C CC AC STICK Mode AC output is not available on all models 40 60 80 100 120 0 20 40 60 80 100 0 100 200 30...

Page 24: ...amperage output capabilities of the welding generator Curves of other settings fall between the curves shown AC output is not available on all models A CC AC TIG Mode B CC DC TIG Mode 4 8 TIG Mode Vol...

Page 25: ...rovided in base Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes NOTICE Do not install unit where air flow is restricted...

Page 26: ...t have GFCI receptacles use GFCI protected extension cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground termina...

Page 27: ...ns Stop fueling when fuel level reaches neck tube Do not top off tank Always leave filler neck empty to allow room for expansion Check fuel level on a cold engine be fore use each day To check fuel le...

Page 28: ...ifications Stop fueling when fuel level reaches neck tube Do not top off tank Always leave filler neck empty to allow room for expansion Check fuel level on a cold engine be fore use each day To check...

Page 29: ...on EFI System And Battery Information NOTICE EFI system components can be damaged if these precautions are not followed Do not allow the battery cables to touch opposing terminals When connecting the...

Page 30: ...electrode holder TIG torch cable to Stick TIG CC terminal DC Models 4 Negative Weld Output Terminal 5 Stick TIG Weld Output Terminal 6 Wire Weld Output Terminal For MIG welding connect work cable to...

Page 31: ...ble size Turn off power be fore connecting to weld output termi nals Do not use worn damaged under sized or poorly spliced cables Weld Output Terminals Weld Cable Size and Total Cable Copper Length in...

Page 32: ...e at Run speed in all Wire modes 115 VOLTS AC I 115 volts ac Protected by supplementary protec tor CB3 J Contact closure to I completes 115 volts AC con tactor control circuit REMOTE OUTPUT CONTROL C...

Page 33: ...A complete Parts List is available at www MillerWelds com OM 4426 Page 29 Notes...

Page 34: ...A complete Parts List is available at www MillerWelds com OM 4426 Page 30 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 Ref 287 062 Ref 227 723 A 4 2 1 3 5 9 7 8 6...

Page 35: ...ers to de termine total engine hours and hours until next recommended oil change see items 3 and 4 earlier in this section The unit will not return to idle speed when the remote contactor is on and Pr...

Page 36: ...his setting provides a high dig arc force for open root vertical down joints where additional current is needed to compensate for tight joint fit up without the need to increase overall welding curren...

Page 37: ...lectrode Hot Lift Arc w Auto Stop TIG GTAW Lift Arc w Auto Stop GTAW DC Only Electrode Hot TIG Remote On Off TIG GTAW With HF Unit Pulsing Device Or Remote Control AC or DC At Remote Receptacle Stick...

Page 38: ...piece at weld start point Slowly lift electrode Arc is started when electrode is lifted Maintain shielding gas coverage and eliminate tungsten and work piece contamination by using Auto Crater or Auto...

Page 39: ...ntrol Optional 3 Remote Foot Control Optional Engine runs at weld power speed in Wire mode whenever a device connected to the re mote receptacle makes clo sure between pins A and B In all other modes...

Page 40: ...AC output to RC4 stops Press button to re set If supplementary protector continues to open contact Factory Authorized Ser vice Agent Combined output of all receptacles limited to peak rating of the ge...

Page 41: ...2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Pl...

Page 42: ...A complete Parts List is available at www MillerWelds com OM 4426 Page 38 SECTION 8 MAINTENANCE TROUBLESHOOTING 8 1 Maintenance Label...

Page 43: ...Engine Manual Section 8 6 8 7 Unreadable Labels Spark Plug Gap Oil Filter Fuel Filter Every 500 Hours Engine Manual Weld Cables Slip Rings Brushes Valve Clearance NOTICE This equipment meets US EPA E...

Page 44: ...e broken or missing 1 4 in 1 Tools Needed 8 5 Servicing Air Cleaner aircleaner3 11 04 802 772 803 070 S 0759 Stop engine NOTICE Do not run engine with out air cleaner or with dirty element 1 Precleane...

Page 45: ...l and running engine Fill crankcase with new oil to full mark on dipstick see Section 5 5 3 Secondary Fuel Filter EFI Models Only 4 Primary Fuel Filter 5 Fuel Line Replace line if cracked or worn Inst...

Page 46: ...lve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 5 6 3 Fuel Filter 4 Fuel Line Replace line if cracked or worn Install new filter...

Page 47: ...s weld power speed adjustments Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screw 3 Idle Speed Screw Loosen mounting screw Adjust so lenoid posi...

Page 48: ...justments Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screw 3 Idle Speed Screw Loosen mounting screw Adjust so lenoid position so engine runs a...

Page 49: ...mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid li...

Page 50: ...cts the stator winding supplying 24 volt AC output to Re mote receptacle RC4 If CB4 opens 24 volt AC output to RC4 stops Supplementary protectors CB1 and CB3 protect the stator winding supplying 115 v...

Page 51: ...trol board PC2 Erratic weld output Check control settings Clean and tighten connections both inside and outside unit Check and secure lead connections to remote control Be sure connection to work piec...

Page 52: ...uthorized Service Agent check brushes slip rings and field current control board PC2 Check receptacle wiring and connections Check governor according to engine manual 8 14 Engine Troubleshooting Troub...

Page 53: ...lace Process Contactor switch in Electrode Hot position or turn off remote contactor The unit will not return to idle speed when Process Contactor switch is in a remote position and the remote contact...

Page 54: ...Filter Wrapper 1 246115 Tune up Filter Kit Kohler ECH730 includes 1 230016 Air Filter Element 1 066698 Oil Filter 1 246117 Filter Fuel w Clamps Primary 1 246123 Filter Fuel w Clamps Secondary 1 06700...

Page 55: ...e at www MillerWelds com OM 4426 Page 51 Notes BUTT BUTT BUTT BUTT T JOINT T JOINT T JOINT T JOINT FILLET GROOVE FLAT VERTICAL HORIZONTAL OVERHEAD WELD POSITION WELD JOINT TYPES Ref AWS ANSI D1 1 1G 1...

Page 56: ...OM 4426 Page 52 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Welding Generator Models With AC DC Output...

Page 57: ...OM 4426 Page 53 251 540 A...

Page 58: ...OM 4426 Page 54 Figure 10 2 Circuit Diagram For Welding Generator Models With DC Output Only...

Page 59: ...OM 4426 Page 55 251 539 A...

Page 60: ...azards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehi...

Page 61: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Page 62: ...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 63: ...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 64: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Page 65: ...back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch In...

Page 66: ...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 Use GFCI protection when operating auxiliary e...

Page 67: ...ontrols and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils...

Page 68: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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