Miller Trailblazer 325 Diesel Owner's Manual
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Miller Trailblazer 325 Diesel Owner's Manual

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OM-279836L
2020-10
Processes
Multiprocess Welding
Description
Engine Driven Welder/Generator
Trailblazer
325 Diesel
®
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-279836L 2020-10 Processes Multiprocess Welding Description Engine Driven Welder/Generator Trailblazer 325 Diesel ® OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .
  • Page 4 TABLE OF CONTENTS Lift-Arc™ TIG With Auto-Stop™ And Auto-Crater™ ..............35 Remote Voltage/Amperage Control .

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 7: Engine Hazards

    � Never weld on a pressurized cylinder — explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � To reduce possible interference, keep weld cables as short as ARC WELDING can cause possible, close together, and down low, such as on the floor. interference. � Locate welding operation 100 meters from any sensitive electronic equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- � Ne pas souder dans des endroits situés à proximité d’opérations champ les pièces endommagées. Entretenir l’appareil conformé- de dégraissage, de nettoyage ou de pulvérisation. La chaleur et ment à ce manuel. les rayons de l’arc peuvent réagir en présence de vapeurs et for- mer des gaz hautement toxiques et irritants.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Le soudage effectué sur un plafond, plancher, paroi ou séparation Les CHAMPS peut déclencher un incendie de l’autre côté. ÉLECTROMAGNÉTIQUES (CEM) � Ne pas couper ou souder des jantes ou des roues. Les pneus peu- peuvent affecter les implants vent exploser s’ils sont chauffés.

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas faire le plein en fumant ou proche d’une source d’étincelles � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- ou d’une flamme nue. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    MÉTAL CHAUD provenant du Une PRESSION D’AIR RÉSIDUELLE découpage ou du gougeage à l’arc ET DES FLEXIBLES QUI FOUETTENT risque de provoquer un incendie ou risquent de provoquer des une explosion. blessures. � Détendre la pression pneumatique des outils et circuits avant �...
  • Page 16 � Suivre les consignes du Manuel des applications pour l’équation � Ne charger que des batteries plomb-acide. Ne pas utiliser le char- de levage NIOSH révisée (Publication Nº94-110) lors du levage geur de batterie pour alimenter un autre circuit électrique basse manuelle de pièces ou équipements lourds.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...

  • Page 18: Informations Relatives Aux Cem

    2-8. Informations relatives aux CEM 3. Ne pas courber et ne pas entourer les câbles autour de votre Le courant électrique qui traverse tout conducteur génère des corps. champs électromagnétiques (CEM) à certains endroits. Le courant is- su d’un soudage à l’arc (et de procédés connexes, y compris le sou- 4.

  • Page 19: Section 3 - Definitions

    Safe8 For single phase operation, insulate and isolate red conducto � Include extra length in grounding conductor and connect grou Complete Parts List is available at www.MillerWelds.com conductor first. Connect black, white, and red wires (L1, L2, L Never use generator inside a home or garage, even if doors a SECTION 3 –...
  • Page 20 Alternating Engine Stop Current (AC) Tungsten Inert Gas (TIG) Lift Arc Protective Earth Tungsten Inert Run (Fast) (Ground) � Gas (TIG) Lift Arc Protective Earth Complete Parts List is available at www.MillerWelds.com Run (Fast) (Ground) Engine-Driven 3- Remote Phase Alternator Air Filter Hertz Fuel...

  • Page 21: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 22: Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.MillerWelds.com 4-6. Dimensions, Weights, And Operating Angles Do not exceed tilt angles or engine could be damaged or unit could tip. 1-1. Dimensions, Weights, And Operating Angles Do not move or operate unit where it 1-1.

  • Page 23: Duty Cycle And Overheating

    � Complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating 1 100% Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. � This unit is rated at 325 amperes DC for continuous welding.

  • Page 24: Fuel Consumption

    1-3. Fuel Consumption 1-3. Fuel Consumption � Complete Parts List is available at www.MillerWelds.com 4-9. Fuel Consumption On a typical job using 1/8 in 7018 electrodes Welding Fuel Consumption (125 amps, 20% duty cycle), expect about 24 hours of operation. 1.50 5.68 1.50...

  • Page 25: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com 1-1. Installing Welder/Generator SECTION 5 – INSTALLATION 1-1. Installing Welder/Generator 5-1. Installing Welder/Generator Complete Parts List available at www.MillerWelds.com Do not move or operate unit where Movement it could tip. Do not lift unit from end. Do not weld on base.

  • Page 26: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 1 Equipment Grounding Terminal (On Always ground generator frame to some running gear insulate the Front Panel) vehicle frame to prevent electric...

  • Page 27: Connecting The Battery

    259 703 � Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery 259 707 / Ref. S-0756-D 3/8, 1/2 in. (+) cable to the positive (+) battery ter- � Never use a quick battery charger to Connect negative (–) cable last. philips head wrench crescent wrench...

  • Page 28: Engine Prestart Checks And Overview

    � Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks And Overview OM-279836 Page 24...
  • Page 29 � Complete Parts List is available at www.MillerWelds.com If coolant level is not visible in the filler tee, Oil: Check oil level often and do not use the 1 Generator Power Receptacles (see Sec- tion 7-1) add coolant to overflow bottle. oil pressure shutdown system to monitor oil level.

  • Page 30: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-6. Weld Output Terminals 277086-A Stop engine. 2 Stick/TIG/Gouge Negative (-) Weld Out- For Stick welding, connect work cable to put Terminal Negative (-) terminal and electrode holder Turn off power before connecting to cable to Positive (+) terminal.

  • Page 31: Selecting Cable Sizes

    � Complete Parts List is available at www.MillerWelds.com 5-7. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 32: Connecting To Remote Receptacle

    � Complete Parts List is available at www.MillerWelds.com 5-9. Connecting To Remote Receptacle Remote Socket* Socket Information 24 volts AC. Protected by supplementary protec- tor CB4. 24 Volts AC Output Contact closure to A completes 24 volt AC con- C L N (Contactor) tactor control circuit and keeps engine at Run speed in all Wire modes..

  • Page 33: Section 6 - Operation

    � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Front Panel Controls (See Section 6-2) 277045-B OM-279836 Page 10 OM-279836 Page 29...

  • Page 34: Description Of Front Panel Controls (See Section 6-1)

    Control switch in Run position. by turning Process/Contactor switch to tings adjust: DIG for SMAW processes, Auto another position. NOTICE – Diesel engines in Miller equip- Stop for GTAW processes, and inductance ment are meant to operate optimally at mod- 6 Process/Contactor Switch for FCAW and GMAW processes.

  • Page 35: Process/Contactor Switch

    Engine returns to idle about 3 seconds after � propriate for load. the arc is broken if running at less than 2800 Miller recommends Hobart filler RPM. If running at more than 3200 RPM, re- metals.

  • Page 36: Service Menu

    � Complete Parts List is available at www.MillerWelds.com 6-5. Service Menu 1 Adjust Control/Select Button Press and hold control for 5 seconds, then re- lease to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the options and information within each menu item.

  • Page 37: Arc Control Settings

    � Complete Parts List is available at www.MillerWelds.com 6-6. Arc Control Settings � Arc Control is not active when the Process/Contactor switch is in the following positions: Output On: CAC-A (Air Carbon Arc Gouging) Remote ON/OFF: GTAW (Remote TIG) Complete Parts List is available Process/Contactor Switch Arc Control Complete Parts List is available...

  • Page 38: Stick Start Procedure-Scratch Start Technique

    Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. � Miller recommends Hobart filler metals. OM-279836 Page 34...

  • Page 39: Lift-Arc™ Tig With Auto-Stop™ And Auto-Crater

    Remote control is not needed when us- ing Auto-Crater. 1. While welding. 2. Lift torch slightly to start Auto-Crater end (current is reduced). 3. Lower torch. Weld current ramps down. 4. Shielding gas continues until shut off. � Miller recommends Hobart filler metals. OM-279836 Page 35...

  • Page 40: Remote Voltage/Amperage Control

    � Complete Parts List is available at www.MillerWelds.com 6-9. Remote Voltage/Amperage Control 1 Remote Receptacle RC4 Connect optional remote voltage/amperage (V/A) control to RC4 (see Section 5-9). 2 Process/Contactor Switch With remote control connected, weld output in Stick or TIG is determined by a combina- tion of front panel and remote control volt- age/amperage settings.

  • Page 41: 6-10. Updating Software

    � Complete Parts List is available at www.MillerWelds.com 6-10. Updating Software 1-6. Summary File 6-11. Summary File 1 Summary File Each time a USB stick is inserted in the USB receptacle, a summary file is saved to the USB stick as SummaryFile.txt. "USB ACC"...

  • Page 42: Fuel/Hour Gauge Descriptions

    � Complete Parts List is available at www.MillerWelds.com 11-25. Fuel/Hour Gauge Descriptions 6-12. Fuel/Hour Gauge Descriptions OM-279836 Page 38...

  • Page 43: 6-13. Associating Arcreach

    � Complete Parts List is available at www.MillerWelds.com 6-13. Associating ArcReach Devices (ArcReach Models Only) ® Stop engine. NOTICE – Do not exceed machine duty cycle. Associating ArcReach Device To Engine Driven Welder/Generator Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection diagrams.

  • Page 44: Section 7 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Supplementary Protectors RC1 supplies 60 Hz single-phase power at 5 Supplementary Protector CB3 Use GFCI protection when operating weld/power speed. Maximum output is 12.0 auxiliary equipment.

  • Page 45: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 46: Optional Excel Power

    Ref. 248009 � Complete Parts List is available at www.MillerWelds.com 7-3. Optional Excel Power Excel power option provides generator power at idle speed and while welding. This allows most job site tools to operate properly at engine idle speed. Use GFCI protection when operat- ing auxiliary equipment.

  • Page 47: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    � Complete Parts List is available at www.MillerWelds.com 7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 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 re- ceptacle shares a load with one half of 240 V 120V...

  • Page 48: Section 8 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 3 MAINTENANCE AND TROUBLESHOOTING SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label 3-1. Maintenance Label OM-279836 Page 44 OM-279836 Page 16...

  • Page 49: Routine Maintenance

    This flowchart is intended as a general guide only. Al- ways read and follow the safety information and specific � Complete Parts List is available at www.MillerWelds.com instructions given elsewhere in this Technical Manual. 8-2. Routine Maintenance ine-powered welder/generator, always perform the following basic ecks before contacting the engine manufacturer.

  • Page 50: Engine Maintenance Activities

    � Complete Parts List is available at www.MillerWelds.com 8-3. Engine Maintenance Activities Stop engine and let cool. Install new filter as shown. Add engine coolant as follows: Oil And Fuel 5 Fuel Filter 8 Water Bypass Hose 1 Oil Drain Valve Replace filter according to engine manual.

  • Page 51: Replacing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com 8-4. Replacing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty. 1 Air Intake Tube 2 Hose Clamp 3 Air Cleaner...

  • Page 52: Overload Protection

    � Complete Parts List is available at www.MillerWelds.com 8-6. Overload Protection Stop engine. � tools/ When a circuit breaker or fuse opens, it usually indicates a more serious prob- lem exists. Contact a Factory Author- ized Service Agent. 1 Fuse F5 F5 protects the weld excitation winding from overload.

  • Page 53: Voltmeter/Ammeter Error Displays

    � Complete Parts List is available at www.MillerWelds.com 8-7. Voltmeter/Ammeter Error Displays Display Example Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. � When an error is displayed, normally weld output has stopped but generator power output may be okay. �...

  • Page 54: Troubleshooting Tables

    � Complete Parts List is available at www.MillerWelds.com 8-8. Troubleshooting Tables A. Welding Trouble Remedy Low or no weld output; generator Check control settings and all connections. power output okay at AC receptacles. Check fuse F5 and replace if necessary (see Section 8-6). Have Factory Authorized Service Agent check brushes, slip rings, and main rectifiers SR1, SR2, and SR3.
  • Page 55 � Complete Parts List is available at www.MillerWelds.com Trouble Remedy Glow plug circuit breaker CB7 may be open (see Section 8-6). Wait and retry. Service inline fuel strainer and fuel filter (see Section 8-2). Check battery and replace if necessary. Check engine charging system according to engine manual.

  • Page 56: Section 9 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity 284184 USB Flash Drive 259935 Filter Kit, Kubota (Includes air cleaner element, fuel, oil filters) 258349 Air Cleaner, Intake Dry Straight Outlet 213858...
  • Page 57 OM-279836 Page 53...

  • Page 58: Section 10 - Electrical Diagrams

    SECTION 10 – ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-279836 Page 54...
  • Page 59 286608-C OM-279836 Page 55...

  • Page 60: Section 11 - Generator Power Guidelines

    SECTION 11 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 11-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 61 11-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing system.
  • Page 62 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 63 Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 11-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
  • Page 64 11-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 65 11-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 66 11-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)

  • Page 67: Warranty

    Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Supplied Air Respirator (SAR) Boxes and Panels below, Miller Electric Mfg.
  • Page 68 File a claim for loss or damage during For International Locations Visit shipment. www.MillerWelds.com For assistance in filing or settling claims, con- tact your distributor and/or equipment manu- facturer’s Transportation Department. ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2020-10...

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