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TABLE OF CONTENTS

SECTION 7

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OPERATING AUXILIARY EQUIPMENT

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7-1. Generator Power Receptacles And Supplementary Protectors

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7-2. GFCI Receptacle Information, Resetting And Testing

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7-3. Optional Excel Power

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7-4. Simultaneous Weld And Power

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7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

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SECTION 8

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MAINTENANCE & TROUBLESHOOTING

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8-1. Maintenance Label

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8-2. Routine Maintenance

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8-3. EFI System And Servicing Information

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8-4. Servicing Air Cleaner

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8-5. Servicing Optional Spark Arrestor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter

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8-7. Overload Protection

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8-8. Engine Speed Adjustment

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8-9. Welding Troubleshooting

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8-10. Generator Power Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Engine Troubleshooting

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SECTION 9

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PARTS LIST

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9-1. Recommended Spare Parts

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SECTION 10

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ELECTRICAL DIAGRAMS

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SECTION 11

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GENERATOR POWER GUIDELINES

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COMPLETE PARTS LIST

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www.MillerWelds.com

WARRANTY

Содержание Trailblazer 275

Страница 1: ...se TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Engine Driven Welding Generator OM 249 795D 2013 02 Air Plasma Cutting and Gouging with Spectrum Unit Air Carbon Arc CAC A Cutti...

Страница 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...

Страница 3: ...IFICATIONS 15 4 1 Specifications 15 4 2 Dimensions Weights And Operating Angles 16 4 3 Fuel Consumption Curves 17 4 4 Stick Volt Ampere Curves 18 4 5 MIG Volt Ampere Curves 19 4 6 TIG Volt Ampere Curv...

Страница 4: ...40 8 1 Maintenance Label 40 8 2 Routine Maintenance 41 8 3 EFI System And Servicing Information 41 8 4 Servicing Air Cleaner 42 8 5 Servicing Optional Spark Arrestor 42 8 6 Changing Engine Oil Oil Fil...

Страница 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...

Страница 6: ...ks 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 con...

Страница 7: ...e 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 scaldi...

Страница 8: ...PARTS 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 cl...

Страница 9: ...Reduce 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...

Страница 10: ...ebsite 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...

Страница 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...

Страница 12: ...n 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 dan...

Страница 13: ...er 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...

Страница 14: ...imentation 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 com...

Страница 15: ...uer 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...

Страница 16: ...al 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...

Страница 17: ...ian 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...

Страница 18: ...doors and vents Safe88 2012 07 3 2 Miscellaneous Symbol Definitions Stop Engine Fast Run Weld Power Fast Slow Auto Speed Slow Idle Start Engine Panel Local Temperature Fuel Engine Oil Engine Choke Ai...

Страница 19: ...5 A 28 V 100 Duty Cycle 30 275 A 100 VDC Peak 12 kVA kW Continuous 10 5 kVA kW 88 44 A 120 240 V AC 60 Hz Single Phase 12 gal 45 L Tank Kohler CH730 Air Cooled Two Cylinder Four Cycle 25 HP Gasoline E...

Страница 20: ...eights And Operating Angles Ref 251 959 A 20 20 20 20 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 460 lb 209 kg w o fue...

Страница 21: ...4 gallon of fuel per hour Expect about 16 hours of operation with carbureted engine 19 hours with EFI engine 254 853 A Weld Carb Weld EFI Run No Load Carb Run No Load EFI Idle Carb Idle EFI 0 0 50 10...

Страница 22: ...pabilities of the welding generator 4 4 Stick Volt Ampere Curves 0 50 100 150 200 250 300 350 AMPERES 400 30 A 150 A Stiff 25 150 A Soft 25 0 10 20 30 40 50 60 70 80 90 100 VOLTS CC DC XX10 Electrode...

Страница 23: ...erator 4 5 MIG Volt Ampere Curves 0 50 100 150 200 250 300 350 AMPERES 400 13 Volts 25 Volts 35 Volts 0 10 20 30 40 50 60 70 80 90 100 VOLTS 257 137 The volt ampere curves show the minimum and maximum...

Страница 24: ...rcentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 4 7 Duty Cycle 254 868 A 100 dutycycle Continuous Welding Note...

Страница 25: ...les provided 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 restri...

Страница 26: ...ptacles to power life support 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...

Страница 27: ...eaches Max Fill Level on tank Do not top off tank Always leave room for expansion Check fuel level on a cold engine before use each day To check fuel level turn Engine Con trol switch to Auto Speed po...

Страница 28: ...jection 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...

Страница 29: ...3 Wire TIG Gouge Negative Weld Output Terminal For MIG welding connect work cable to Negative terminal and wire feeder cable to Positive terminal For Stick welding connect work cable to Negative term...

Страница 30: ...re connecting to weld output terminals Weld Output Terminals Do not use worn damaged under sized or poorly spliced cables Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 10...

Страница 31: ...d keeps engine at Run speed in all Wire modes REMOTE OUTPUT CONTROL C 10 volts dc output to remote control D Remote control circuit common E 0 to 10 volts dc input command signal from remote control F...

Страница 32: ...Complete Parts List is available at www MillerWelds com OM 249 795 Page 28 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 248 009 A 251 160 A 1 2 3 4 5 6 7 8 9...

Страница 33: ...selected TIG Gouge Flux Core 6 Fuel Level Indicator With Engine running or Engine Control switch in Run or Auto Speed position LED s indicate fuel left in tank 7 Engine Choke Control Carbureted Engine...

Страница 34: ...rs in severe cold continuously below 0 F Moisture accumulates in the oil from piston ring blow by if the engine is exten sively idled This may cause vacuum line freezing oil breather tube freezing or...

Страница 35: ...en using a XX18 type 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...

Страница 36: ...g 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 XX13 XX14 XX24 and...

Страница 37: ...s 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...

Страница 38: ...when 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 l...

Страница 39: ...eld 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 803 571 A 248 009 A...

Страница 40: ...power 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...

Страница 41: ...and test GFCI receptacle according to the following procedures Resetting Testing GFCI Receptacle Test GFCI monthly See Testing GFCI Receptacle Do not test or reset GFCI recept acles at idle speed low...

Страница 42: ...ent 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 does not provide...

Страница 43: ...lug 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 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Loa...

Страница 44: ...Complete Parts List is available at www MillerWelds com OM 249 795 Page 40 SECTION 8 MAINTENANCE TROUBLESHOOTING 8 1 Maintenance Label...

Страница 45: ...lement Every 200 Hours Engine Manual and Section 8 6 Unreadable Labels Spark Plug Gap Oil Filter Fuel Filter Every 500 Hours Engine Manual Weld Cables Slip Rings Brushes NOTICE This equipment meets US...

Страница 46: ...precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty...

Страница 47: ...ing engine Fill crankcase with new oil to full mark on dipstick see Section 8 1 2 Fuel Filter 3 Fuel Line Replace line if cracked or worn Install new filter with arrow pointing in the direction of fue...

Страница 48: ...indings from overload If CB5 opens Excel power is not available at receptacle RC3 Place switch in On position to reset 3 Fuse F6 See Parts List F6 protects the engine wiring sys tem from overload If F...

Страница 49: ...t be adjusted Have Factory Authorized Service Agent check control board PC2 Erratic weld output Check weld control settings Clean and tighten connections both inside and outside unit Check and secure...

Страница 50: ...ngine Factory Authorized Service Agent check engine speed See engine manual No weld output and no auxiliary power Have Factory Authorized Service Agent check fuse F5 High power output Have engine Fact...

Страница 51: ...5 5 Low oil pressure shutdown stops engine if oil pressure is too low Oil level too high reduces capacity of the fuel pump carbureted engines only Have Factory Authorized Service Agent check fuel shut...

Страница 52: ...ler CH730 Includes 1 230016 Air Filter Element 1 066698 Oil Filter 1 215985 Filter Fuel w Clamps 1 4 in Fuel Line 1 067007 Spark Plug 2 230017 Air Filter Wrapper 1 246115 Tune up Filter Kit Kohler ECH...

Страница 53: ...OM 249 795 Page 49 SECTION 10 ELECTRICAL DIAGRAMS 249 792 E Figure 10 1 Circuit Diagram For 275 Model Welding Generator...

Страница 54: ...OM 249 795 Page 50 247 672 E Figure 10 2 Circuit Diagram For 325 Model Welding Generator...

Страница 55: ...ealth 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 fr...

Страница 56: ...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 approxi mately six times more power while starting the motor than when...

Страница 57: ...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...

Страница 58: ...HP 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...

Страница 59: ...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 Vol...

Страница 60: ...d 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...

Страница 61: ...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...

Страница 62: ...OM 249 795 Page 58 Notes...

Страница 63: ...lies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard...

Страница 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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