Miller TRAILBLAZER 275 DC Owner's Manual
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Miller TRAILBLAZER 275 DC Owner's Manual

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Trailblazer 302
Trailblazer 275 DC
OM-4426
2012−03
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
(AC Available On AC/DC Models Only)
R
R
File: Engine Drive
215 348AD
R
Unit

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  • Page 1 TIG (GTAW) Welding Air Plasma Cutting and Gouging with Spectrum Unit Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator (AC Available On AC/DC Models Only) Trailblazer 302 Trailblazer 275 DC File: Engine Drive Visit our website at 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 ....... . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING AUXILIARY EQUIPMENT ......... . . 7-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−10 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 Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 6 D Do not weld on containers that have held combustibles, or on FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Welding produces fumes and gases. Breathing these Safety Standards).

  • Page 7: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.

  • Page 10: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−10 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 Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.

  • Page 14: Dangers Liés À L'air Comprimé

    LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro- REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et provoquer des brûlures. sur la PEAU. D Il est préférable de vérifier le liquide de refroi- D Ne pas renverser la batterie. dissement une fois le moteur refroidi pour éviter D Remplacer une batterie endommagée.

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

    détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
  • Page 16 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI- SION BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces. modèles.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.

  • Page 18: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Engine Choke Battery (Engine) Clearance Read Operator’s Engine Amperes Volts...

  • Page 19: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Carbureted Engine Specifications (Subaru EH65, Kohler CH-23) Rated Maximum Weld Welding Generator Fuel Welding Open-Circuit Output Engine Mode Power Rating Capacity Output Voltage Range Subaru EH65 280 A, 25 V, 100% Air-Cooled,...

  • Page 20: Dimensions, Weights, And Operating Angles

    A complete Parts List is available at www.MillerWelds.com 4-3. Dimensions, Weights, And Operating Angles 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: 580 lb (263 kg) °...

  • Page 21: Fuel Consumption Curves

    A complete Parts List is available at www.MillerWelds.com 4-4. Fuel Consumption Curves On a typical job using 1/8 in. 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration with carbureted engine (24 hours with EFI engine). Welding at 150 amps at 40% duty cycle uses about 3/4 gallon of fuel 2.25...

  • Page 22: Generator Power Curve

    A complete Parts List is available at www.MillerWelds.com 4-5. Generator Power Curve The AC generator power curve shows the generator power avail- able in amperes at the receptacles. Tools and motors are designed to operate within 10% of 120/240 VAC. +/−...

  • Page 23: Stick And Mig Mode Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-7. Stick And MIG Mode Volt-Ampere Curves The volt-ampere curves show the A. CC/DC Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown.

  • Page 24: Tig Mode Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-8. TIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/AC TIG Mode the welding generator. Curves of other settings fall between the curves shown.

  • Page 25: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output.

  • Page 26: Grounding Generator To Truck Or Trailer Frame

    A complete Parts List is available at www.MillerWelds.com 5-3. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2011−04 − 800 652-D welding generator from the vehicle Equipment Grounding Terminal (On Always ground generator frame to frame. Always connect a ground Front Panel) vehicle frame to prevent electric wire from the generator equipment...

  • Page 27: Engine Prestart Checks (Kohler-Powered Units)

    A complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks (Kohler-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. This unit has a low oil pressure shutdown switch.

  • Page 28: Engine Prestart Checks (Subaru-Powered Units)

    A complete Parts List is available at www.MillerWelds.com 5-6. Engine Prestart Checks (Subaru-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. This unit has a low oil pressure shutdown switch.

  • Page 29: Connecting Or Replacing The Battery

    A complete Parts List is available at www.MillerWelds.com 5-7. Connecting Or Replacing The Battery Connect negative (−) battery cable last To connect battery, open right side engine access door. Battery Holddown To change battery, remove rear pan- el with baffle and battery holddown. Be sure battery cables are not pinched when installing battery.

  • Page 30: Weld Output Terminals

    A complete Parts List is available at www.MillerWelds.com 5-9. Weld Output Terminals Stop engine. Do not connect to CC and CV terminals at the same time. AC/DC Models: Work Weld Output Terminal Stick/TIG (CC) Weld Output Terminal Wire /CV Weld Output Terminal For MIG welding, connect work cable to Work terminal and wire feeder cable to Wire (CV) terminal.

  • Page 31: Connecting To Weld Output Terminals

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 OM-4426 Page 27...

  • Page 32: Remote Receptacle Information

    A complete Parts List is available at www.MillerWelds.com 5-12. Remote Receptacle Information Engine runs at weld/power speed whenever a device connected to the remote receptacle is running. Socket* Socket Information 24 volts ac. Protected by supplementary protector CB4. 24 VOLTS AC Contact closure to A completes 24 volt AC con- tactor control circuit and keeps engine at Run speed in all Wire modes.
  • Page 33 A complete Parts List is available at www.MillerWelds.com Notes OM-4426 Page 29...

  • Page 34: Section 6 − Operating Welding Generator

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) Ref. 287 062 / Ref. 227 723-A OM-4426 Page 30...

  • Page 35: Description Of Front Panel Controls (See Section 6-1)

    A complete Parts List is available at www.MillerWelds.com 6-2. Description Of Front Panel Controls (See Section 6-1) Process/Contactor Switch In Stick and TIG modes, Voltmeter reads next recommended oil change (see items 3 ON and Ammeter displays preset amperage and 4 earlier in this section). See Section 6-4 for Process/Contactor when not welding.

  • Page 36: Process/Contactor Switch On Ac/Dc Models

    A complete Parts List is available at www.MillerWelds.com 6-4. Process/Contactor Switch On AC/DC Models 803 571−A /287 062−A Process/Contactor Switch descriptions following (reading L to R): Medium Arc - This setting provides me- dium dig/arc force for open root vertical up Weld output terminals are energized Soft Arc (E 7018) - This setting provides a joints or joints that do not require additional...

  • Page 37: Stick Start Procedure − Scratch Start Technique

    A complete Parts List is available at www.MillerWelds.com Table 6-1. Process/Contactor Switch Settings Switch Setting Process Output On/Off Control Electrode Hot − Wire MIG (GMAW) Electrode Hot Stick (SMAW) Electrode Hot − Stick Electrode Hot Select Preferred Dig Air Carbon Arc (CAC-A) Cutting And Gouging Electrode Hot −...

  • Page 38: Lift-Arct Tig With Auto-Cratert And Auto-Stopt

    A complete Parts List is available at www.MillerWelds.com 6-6. Lift-Arct TIG With Auto-Cratert And Auto-Stopt Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Arc Start With Lift-Arc Select Lift-Arc at Process/Contac- tor switch.

  • Page 39: Remote Voltage/Amperage Control

    A complete Parts List is available at www.MillerWelds.com 6-7. Remote Voltage/Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-12). With remote control connected, weld output in a CC mode (Stick, TIG) is determined by a combina- tion of front panel and remote con- trol voltage/amperage settings.

  • Page 40: Section 7 − Operating Auxiliary Equipment

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Supplementary Protectors Ref. 287 062 RC2 and RC3 supply 60 Hz single-phase mote Receptacle RC4 from overload. If If unit does not have GFCI recep- power at weld/power speed.

  • Page 41: Simultaneous Weld And Power

    A complete Parts List is available at www.MillerWelds.com 7-3. Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Receptacle Amperes 240 V Receptacle Amperes 1000 3500 5200 6700 8000 11,000 7-4. 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.

  • Page 42: Section 8 − Maintenance & Troubleshooting

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

  • Page 43: Routine Maintenance

    A complete Parts List is available at www.MillerWelds.com 8-2. Routine Maintenance Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 6-1). The Voltmeter and Ammeter display total engine operating hours at start-up. Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period Stop engine before maintaining.

  • Page 44: Servicing Optional Spark Arrestor

    A complete Parts List is available at www.MillerWelds.com 8-4. Servicing Optional Spark Arrestor Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. Tools Needed: 1/4 in. Ref. 803 572−A / Ref. 183 175−A 8-5.

  • Page 45: Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)

    A complete Parts List is available at www.MillerWelds.com 8-6. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) Stop engine and let cool. Oil Drain Valve Oil Filter Change engine oil and filter accord- ing to engine manual. NOTICE − Close valve and valve cap before adding oil and running engine.

  • Page 46: Changing Engine Oil, Oil Filter, And Fuel Filter (Subaru-Powered Units)

    A complete Parts List is available at www.MillerWelds.com 8-7. Changing Engine Oil, Oil Filter, and Fuel Filter (Subaru-Powered Units) Stop engine and let cool. Oil Drain Valve Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. NOTICE −...

  • Page 47: Adjusting Engine Speed (Kohler Carbureted Units [Ch-23])

    A complete Parts List is available at www.MillerWelds.com 8-8. Adjusting Engine Speed (Kohler Carbureted Units [CH-23]) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 − 2300 rpm Start engine and run until warm. (36.6 −...

  • Page 48: Adjusting Engine Speed (Kohler Efi Units [Ech-730])

    A complete Parts List is available at www.MillerWelds.com 8-9. Adjusting Engine Speed (Kohler EFI Units [ECH-730]) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 − 2300 rpm Start engine and run until warm. (36.6 −...

  • Page 49: Adjusting Engine Speed (Subaru-Powered Units)

    A complete Parts List is available at www.MillerWelds.com 8-10. Adjusting Engine Speed (Subaru-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Open top cover access panel to ac- cess speed adjustments.

  • Page 50: Overload Protection

    A complete Parts List is available at www.MillerWelds.com 8-11. Overload Protection Stop engine. Open left side door. When a supplementary protec- tor or fuse opens, it usually in- dicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. Supplementary Protector CB4 CB4 protects the stator winding supplying 24 volt AC output to Re-...

  • Page 51: Welding Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 8-12. Welding Troubleshooting Trouble Remedy No weld output. Check weld control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Increase front panel and/or remote voltage/amperage control settings (see Sections 5-12 and 6-1). Check and secure connections to Remote receptacle RC4 (see Sections 5-12).

  • Page 52: Generator Power Troubleshooting

    A complete Parts List is available at www.MillerWelds.com Trouble Remedy Wandering arc − poor control of arc Reduce gas flow rate. direction. Select proper size tungsten. Properly prepare tungsten. Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of weld.
  • Page 53 A complete Parts List is available at www.MillerWelds.com Trouble Remedy Battery discharges between uses. Place Engine Control switch in Off position when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months).

  • Page 54: Section 9 − Parts List

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity Recommended Spare Parts ....215621 Fuse, 30 Amp Ato Type .
  • Page 55 A complete Parts List is available at www.MillerWelds.com Notes WELD POSITION: FLAT HORIZONTAL VERTICAL OVERHEAD BUTT BUTT WELD JOINT BUTT BUTT TYPES T−JOINT T−JOINT GROOVE T−JOINT FILLET T−JOINT Ref. 804 248-A Ref. AWS/ANSI D1.1 OM-4426 Page 51...

  • Page 56: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models With AC/DC Output OM-4426 Page 52...
  • Page 57 251 540-A OM-4426 Page 53...
  • Page 58 Figure 10-2. Circuit Diagram For Welding Generator Models With DC Output Only OM-4426 Page 54...
  • Page 59 251 539-A OM-4426 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 welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 61 11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring 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 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 64 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 65 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
  • Page 66 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes)
  • Page 67 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 68 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co. 2012−01...

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Trailblazer 302

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