Miller Trailblazer 325 Diesel Owner'S Manual Download Page 1

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Trailblazer 325 Diesel

Processes

Description

Non-Critical TIG (GTAW)

Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Engine Driven Welder/Generator

OM-258900H

2017

−

File: Engine Drive

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Summary of Contents for Trailblazer 325 Diesel

Page 1: ...Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welder Generator OM 258900H 2017 10 File Engine Drive For product information Owner s Manual tra...

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: ...2 Miscellaneous Symbol Definitions 15 SECTION 4 SPECIFICATIONS 17 4 1 Serial Number And Rating Label Location 17 4 2 Weld Power and Engine Specifications 17 4 3 Environmental Specifications 17 4 4 Dim...

Page 4: ...240 Volt Single Phase Plug NEMA 14 50P 40 SECTION 8 MAINTENANCE AND TROUBLESHOOTING 41 8 1 Routine Maintenance 41 8 2 Maintenance Label And Engine Maintenance Activities 42 8 3 Replacing Air Cleaner...

Page 5: ...gh 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 m...

Page 6: ...g sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bu...

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

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

Page 9: ...any metal when threading welding wire OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filte...

Page 10: ...e 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 10036 phone 212 642 4900 web site ww...

Page 11: ...appareil 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...

Page 12: ...essures ou m me la mort Fermer l alimentation du gaz comprim en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAY...

Page 13: ...ication sp cifique les maintenir ainsi que les l ments associ s en bon tat Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gul...

Page 14: ...ppement 2 4 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou m me la mort Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d...

Page 15: ...tretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l installation l entre...

Page 16: ...canique en enga geant le fil de soudage L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Laisser l quipement refroidir respecter le fac teur de marche nominal R duire le courant ou le facteur de marche...

Page 17: ...auga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Ins...

Page 18: ...OM 258900 Page 14...

Page 19: ...s and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 3 2 Miscellaneous Symbol Definitions A Amperage V Voltage Hertz X Duty Cycle...

Page 20: ...Fuel Battery Engine Air Filter Engine Engine Engine Start Engine RPM Engine Engine Stop Glow Plug Idle Slow Run Fast Output On Remote Belt Drive Temperature Engine Coolant Temperature Check Valve Clea...

Page 21: ...bient air temperature up to 1045F 405C Welding Mode Rated Welding Output Maximum Open Circuit Voltage Weld Output Range Generator Power Rating Fuel Capacity Engine CC DC 325 A 33 V 100 Duty Cycle 100...

Page 22: ...8 4 4 Dimensions Weights And Operating Angles 259 701 259 702 Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip Weight 638 lb 289 kg...

Page 23: ...arranty 4 5 Duty Cycle 1 260 048 A 4 6 Static Output Characteristics The static output characteristics voltage with respect to amperage of the welding power source can be described as flat during the...

Page 24: ...expect about 24 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 1 2 gal lon per hour or about 22 hours of operation 0 00 0 25 0 50 0 75 1 00 1 25 1 50 0 50 100 150 200 250...

Page 25: ...where air flow is restricted or engine may over heat See Section 4 4 for lifting eye rat ing Mounting Do not mount unit by support ing the base only at the four mounting holes Do not use flexible mou...

Page 26: ...ort equipment 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger...

Page 27: ...t allow the battery cables to touch opposing terminals When connect ing the battery cables attach the positive cable to the positive battery termin al first followed by negative cable to negative batt...

Page 28: ...als see Section 5 6 3 Operator Controls see Section 6 4 Voltmeter And Ammeter Displays 5 Fuel Level Indicators 6 Fuel Filler Cap 7 Exhaust Pipe 8 Oil Fill Cap 9 Water Bypass Hose 10 Radiator Cap 11 En...

Page 29: ...mixture Running out of fuel air in fuel lines Using gasoline Using ether or other starting fluids to start engine Engine stops if oil pressure is low engine coolant temperature is high or fuel level i...

Page 30: ...eld Output Terminal 2 Stick Negative Weld Output Terminal 3 Wire TIG Gouge Negative Weld Output Terminal For MIG welding connect work cable to Negative terminal and wire feeder cable to Positive termi...

Page 31: ...95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 This chart is a general guideline and may not suit all applications If cable overheats use next size large...

Page 32: ...ary protector CB4 B Contact closure to A completes 24 volt AC con tactor control circuit and keeps engine at Run speed in all Wire modes REMOTE OUTPUT CONTROL C 10 volts dc output to remote control D...

Page 33: ...Complete Parts List available at www MillerWelds com OM 258900 Page 29 Notes...

Page 34: ...Complete Parts List available at www MillerWelds com OM 258900 Page 30 SECTION 6 OPERATING WELDER GENERATOR 6 1 Front Panel Controls See Section 6 2 258 899 B 250 071 A 1 3 4 5 6 7 8 9 2...

Page 35: ...Control switch in Run or Auto Speed position LED s indicate fuel left in tank 7 Glow Plug Switch If necessary push switch down before start up to activate glow plug See glow plug table above for opera...

Page 36: ...electrode Arc Control is set for Soft and the value is shown on the meters Engine Auto Speed When Engine Control switch is in Auto Speed position the engine speed varies depending on the welding load...

Page 37: ...ductance 0 Starting point for mild steel wire STIFF Starting point for aluminum wire low inductance SOFT Flat or horizontal welds with XX18 electrode with short weld cables 0 Starting point for XX18 X...

Page 38: ...per second Meters display aver age output Auto Stop feature allows arc to be broken without loss of shielding gas Not Active No Lift Arc start use external high frequency device or scratch start TIG S...

Page 39: ...hen HF Start method is not permitted Select Lift Arc at Process Contac tor switch Turn gas on 1 Touch or scratch 2 Lift at any angle Touch tungsten electrode to workpiece at weld start point Slowly li...

Page 40: ...ld output in Stick or TIG is deter mined by a combination of front panel and remote control voltage amperage settings In Wire weld output is controlled through remote control only 259 872 248 009 A S...

Page 41: ...wer at weld power speed Maximum output is 12 0 kVA kW RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum out put from RC2 or RC3 is 2 4 kVA kW 3 Supplementary Protector CB1 CB1 pr...

Page 42: ...ated to ground faults Reset and test GFCI receptacle according to the following procedures A solid green LED indicates power to the GFCI A solid red LED indicates that the GFCI has been tripped Resett...

Page 43: ...support equip ment 1 120 V 20 A AC Excel Power Receptacle This receptacle supplies 2 4 kVA kW of pure 120 V 60 Hz sine wave power at ALL engine speeds Circuit protection is provided by CB3 only CB1 d...

Page 44: ...hen wired for 120 V loads each duplex receptacle shares a load with 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 Ter...

Page 45: ...ery 8 Hours Section 5 5 Coolant Level Fuel Level Oil Level Oil Fuel Spills Every 200 Hours Fuel Connections Oil Oil Filter Air Cleaner Section 8 2 8 3 Engine Manual Battery Terminals Unreadable Labels...

Page 46: ...g to engine manual Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up fuel Coolant 6 Radiator Cap 7 Radiator Drain Cock Located on...

Page 47: ...Complete Parts List available at www MillerWelds com OM 258900 Page 43 259 872 258 899 C...

Page 48: ...damage caused by using a damaged ele ment is not covered by the warranty 1 Air Intake Tube 2 Hose Clamp 3 Air Cleaner Loosen hose clamp slide air cleaner to wards rear of unit and remove Slide new air...

Page 49: ...al Excel power windings from overload If this opens Excel power is not available at receptacle RC3 Place switch in On position to reset 3 Circuit Breaker CB7 CB7 protects the engine glow plug circuit...

Page 50: ...coils from weld cables Clean and tighten connections both inside and outside welder generator Have Factory Authorized Service Agent check brushes and slip rings B Generator Power Trouble Remedy No or...

Page 51: ...ngine will not start if engine temperature is too high Have Factory Authorized Service Agent check low oil pressure shutdown switch S3 and engine tem perature switch S4 Engine stopped during normal op...

Page 52: ...s 1 258349 Air Cleaner Intake Dry Straight Outlet 1 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 259934 Filter Fuel Kubota 1 187443 Oil Filter 1 259949 Belt Fan 1 GLOW PLUG 187820 Glow Plug 1 F5...

Page 53: ...Complete Parts List available at www MillerWelds com OM 258900 Page 49 Notes...

Page 54: ...OM 258900 Page 50 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Welder Generator...

Page 55: ...OM 258900 Page 51 258849 E...

Page 56: ...alth Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable fro...

Page 57: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approximatelysix times more power while starting the motor than when ru...

Page 58: ...e 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 Milk...

Page 59: ...00 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10 500 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 Cultivat...

Page 60: ...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 61: ...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 I...

Page 62: ...0 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...

Page 63: ...Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable co...

Page 64: ...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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