Miller Trailblazer 302 Diesel Owner's Manual
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Miller Trailblazer 302 Diesel Owner's Manual

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Trailblazer 302 Diesel
OM-217 454B
2005−10
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
AC/DC TIG (GTAW) Welding
Description
Engine Driven Welding Generator
R
File: Engine Drive

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  • Page 1 OM-217 454B 2005−10 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding AC/DC TIG (GTAW) Welding Description Engine Driven Welding Generator Trailblazer 302 Diesel 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 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − ELECTRICAL DIAGRAMS ............SECTION 10 −...

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. Welding on closed containers, such as tanks, drums, or D Allow cooling period before working on equipment. pipes, can cause them to blow up. Sparks can fly off from the welding arc.

  • Page 7: Compressed Air Hazards

    D Use only genuine Miller/Hobart replacement parts. 1-5. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. ARC WELDING can cause interference. D Use only genuine MILLER/Hobart replacement D Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as D Perform engine and air compressor (if applicable) robots.

  • Page 9: Signification Des Symboles

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles signi- présente des risques de danger ! Ceux-ci sont identifiés fie Mise en garde ! Soyez vigi-...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chaudes. Le soudage effectué sur des conteneurs fermés tels que des D Prévoir une période de refroidissement avant de travailler à réservoirs, tambours ou des conduites peut provoquer leur l’équipement.

  • Page 11: Dangers Liés À L'air Comprimé

    éléments ou avant d’ouvrir la fectuer la maintenance. purge ou le bouchon de remplissage d’huile. D Utiliser uniquement des pièces de rechange Miller/Hobart. 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance L’EMPLOI EXCESSIF peut...

  • Page 12: Proposition Californienne 65 Avertissements

    LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de provoquer des interférences. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur D L’énergie électromagnétique risque de provoquer des in- (si applicable) suivant ce manuel et le manuel du moteur/ terférences pour l’équipement électronique sensible tel compresseur (si applicable).
  • Page 13 Notes OM-217 454 Page 9...

  • Page 14: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch while Temperature Work Connection Clearance welding Alternating Current Positive Negative...

  • Page 15: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Y Always securely fasten weld- Y Do not lift unit from end. ing generator onto transport vehicle or trailer and comply with all DOT and other applica-...

  • Page 16: Dimensions, Weights, And Operating Angles

    5-2. Dimensions, Weights, and Operating Angles Dimensions 35−1/2 in ( 902 mm) Height (To Top Of Exhaust) Width 20 in (508 mm) Y Do not exceed tilt angles or engine could Y Do not exceed tilt angles or engine could be damaged or unit could tip.

  • Page 17: Activating The Dry Charge Battery (If Applicable)

    5-4. Activating The Dry Charge Battery (If Applicable) Y Always wear a face shield, rubber gloves and protective clothing when working on a battery. Remove battery from unit. Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 18: Overview And Engine Prestart Checks

    5-6. Overview And Engine Prestart Checks Generator Power Receptacles (see Radiator Cap 13 Oil Drain Section 7) Engine Maintenance Label (Inside Door) 14 Oil Dipstick Weld Output Terminals (see Section 5-7) Oil Fill Cap 15 Inline Fuel Strainer Operator Controls (see Section 6) 10 Thermostat Housing Plug 16 Air Cleaner Fuel Level Indicators...
  • Page 19 Engine must be cold and on a level sur- Y Engine shown with face. See maintenance label (Section 8-2) doors removed. Doors for fluid specifications. must be in place when engine is running. Starting engine for the first time: Add fresh fuel to bottom of filler neck. Open fuel shut-off valve.

  • Page 20: Connecting To Weld Output Terminals

    5-7. Connecting to Weld Output Terminals Y Do not connect to CC and CV terminals at the same time. 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 21: Selecting Weld Cable Sizes

    5-8. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)

  • Page 22: Adjusting Wire (Mig) Weld Puddle Consistency

    5-10. Adjusting Wire (MIG) Weld Puddle Consistency Y Stop engine and let cool. Stabilizer DC-Z is factory connected to suit most Wire (MIG) welding applications. To change Wire (MIG) weld puddle consis- tency, proceed as follows: Remove right side panels. Stabilizer DC-Z Stabilizer Tabs 1, 2, and 3 Tab 3 −...

  • Page 23: Section 6 − Operating The Welding Generator

    SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Engine Control Switches Controlling Engine Speed 2450 rpm (Idle Speed) Continuous 3750 rpm max (Weld/Power Speed) Continuous. Use in welding applications where high speed is needed for better arc starting and in TIG applications using a high frequency arc starter.

  • Page 24: Weld Output Controls

    6-2. Weld Output Controls Ref. 216 171-A / Ref. 225 915-A Process/Contactor Switch Meter Engine And Maintenance Functions: When a remote voltage/amperage control is See inset from maintenance label. connected to the Remote receptacle, the Auto See Section 6-3 for Process/Contactor switch Sense Remote feature automatically switches information.

  • Page 25: Process/Contactor Switch

    6-3. Process/Contactor Switch Ref. 804 195-A / Ref 216 171-A Process/Contactor Switch or wire feeder using remote control. vertical up joints or joints that do not require additional current for fit up inconsistencies. Stick Positions: Y Weld output terminals are energized when Process/Contactor switch is Use Stick positions for stick (SMAW) and Stiff Arc (E6010) (Position 4) - This setting...

  • Page 26: Stick Start Procedure − Scratch Start Technique

    6-4. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: Electrode Workpiece Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

  • Page 27: Remote Amperage Control

    6-6. Remote Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-9). 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 28: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles Y If unit does not have GFCI recep- tacles, use GFCI-protected extension cord. Generator power decreases as weld current increases. 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power at weld/power speed.

  • Page 29: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    7-2. 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. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each duplex receptacle shares a load 240 V...
  • Page 30 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org OM-217 454 Page 26...

  • Page 31: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Y Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace...

  • Page 32: Maintenance Label And Engine Maintenance Activities

    8-2. Maintenance Label And Engine Maintenance Activities OM-217 454 Page 28...
  • Page 33 Y Stop engine and let cool. Install new filter as shown. Add engine coolant as follows: Oil And Fuel Fuel Filter Thermostat Housing Plug Oil Drain Valve Replace filter according to engine manual. Remove thermostat housing plug. Add cool- Oil Filter Wipe up any spilled fuel.

  • Page 34: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.

  • Page 35: Adjusting Engine Speed

    8-4. Adjusting Engine Speed NOTE If the engine does not start and stop properly, verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following). If the engine does not stay at idle speed, verify the throttle solenoid is installed and adjusted properly before adjusting engine speed (see Section B following).
  • Page 36 B. Checking Throttle Solenoid Y Stop engine. If the engine does not stay at idle speed, verify the the throttle sole- noid and linkage is installed proper- Adjusting Throttle Solenoid Throttle Solenoid Jam Nut Solenoid Link Shoulder Bolt Throttle Lever Solenoid Rod Throttle Solenoid Mounting Screw...
  • Page 37 C. Making Engine Speed Adjustments Before adjusting engine speed, verify throttle solenoid is installed properly (see Section B on previous page). 2375−2450 rpm Check engine speeds (see table) with a 39.6−40.8 Hz Idle tachometer or use maintenance displays as follows: With engine running and the 3675−3750 rpm Process Selector switch in any Stick HOT 61.3−62.5 Hz...

  • Page 38: Overload Protection

    8-5. Overload Protection Y Stop engine. When a circuit protecotr opens, it usually indicates a more seri- ous problem exists. Contact a Factory Authorized Service Agent. Supplementary Protector CB4 (Located On Fuel Tank Cover) CB4 protects the stator winding supplying 24 volt ac output to Re- mote receptacle RC4.

  • Page 39: Troubleshooting Tables

    8-6. Troubleshooting Tables A. Welding 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 6-2 and 6-6). Check and secure connections to Remote receptacle RC4 (see Sections 5-9). Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
  • Page 40 Trouble Remedy Lack of high frequency; difficulty in Use proper size tungsten for welding amperage. establishing Gas Tungsten Arc Weld- ing arc. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.). Check cables and torch for cracked or deteriorated insulation or bad connections.
  • Page 41 Trouble Remedy Engine starts but stops when Engine Check oil level (see Section 5-6). Engine will not start if oil pressure is too low. Control switch S2 returns to Run/Idle position. Check coolant level and fan belt (see Section 5-6 and engine manual). Engine will not start if engine temperature is too high.

  • Page 42: Recommended Spare Parts

    8-7. Recommended Spare Parts Dia. Part Mkgs. Description Quantity Recommended Spare Parts ....187441 Element, Air Cleaner ..........
  • Page 43 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-217 454 Page 39...

  • Page 44: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-217 454 Page 40...
  • Page 45 215 259-B OM-217 454 Page 41...

  • Page 46: Section 10 − Run-In And Wetstacking

    SECTION 10 − RUN-IN AND WETSTACKING run_in_D722 9/05 10-1. Run-In And Wetstacking Welding Generator Run-in procedures for this engine should not be required. Put unit into regular service. Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs if the engine is run too long at light load or idle rpm.

  • Page 47: Section 11 − Performance Data

    SECTION 11 − PERFORMANCE DATA 11-1. Fuel Consumption Curves Weld Fuel Consumption 2.00 1.75 1.50 1.25 1.00 Weld 3600 0.75 0.50 Idle 0.25 0.00 DC Weld Ampers At 100% Duty Cycle Auxiliary Power Fuel Consumption 1.20 1.00 0.80 0.60 0.40 Idle 0.20 0.00...

  • Page 48: Generator Power Curve

    11-2. Generator Power Curve The ac generator power curve shows the generator power avail- able in amperes at the receptacles. AC Amperes At 120 V AC Amperes At 240V 226 760-A 11-3. Duty Cycle Duty cycle is the percentage of 10 100% Duty Cycle at 280 Amperes DC minutes that unit can weld at rated load without overheating.

  • Page 49: Stick Mode Volt-Ampere Curves

    11-4. Stick 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. Amps CC/AC STICK Mode Amps 226 756-A / 223 761-A OM-217 454 Page 45...

  • Page 50: Tig Mode Volt-Ampere Curves

    11-5. TIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of A. CC/AC TIG Mode other settings fall between the curves shown. Amps B. CC/DC TIG Mode Amps 226 758-A / 226 759-A OM-217 454 Page 46...

  • Page 51: Mig Mode Volt-Ampere Curve

    11-6. MIG Mode Volt-Ampere Curve The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. Amps 226 757-A OM-217 454 Page 47...

  • Page 52: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...
  • Page 53 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 54 12-5. 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 55 12-7. 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 56 12-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 57 12-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Fused Utility Welding Disconnect Electrical Generator Transfer Switch Switch Service Output (If Required) Essential Loads Y Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-...
  • Page 58 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)
  • Page 59 Note A complete Parts List is available on-line at www.MillerWelds.com Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 63 Effective January 1, 2005 (Equipment with a serial number preface of “LF” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.
  • Page 64 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. © PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05...

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