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Summary of Contents for Miller HJ134589
- Page 1 April 1978 FORM: OM-457C Effective With Serial No. HJ134589 MODEL Trailblazer 22G OWN ERS ITIIIIER MANUAL MILLER ELECTRIC MFG. CO. 718 S. BOUNDS ST. P.O. Box 1079 APPLETON, 54912 USA NWSA CODE NO. 4579 PRINTED IN U.S.A.
- Page 2 LIMITED WARRANTY This warranty clusive with LIMITED WARRANTYMiller Electric Customer ton, Wisconsin that all warrants furnished Miller Equipment material workmanship delivery by Miller. warranty trade accessories engines, respect factured others. Such trade accessories and other engines, items sold subject warranties of their manufacturers, manufacturers any.
- Page 3 After this manual printed, refinements this manual. AMENDMENT TO SECTION 3 Amend Section 3-3. EQUIPMENT GROUNDING TERMINAL Normally engine-driven welding generators plant capability; therefore, grounding machine For these quire grounding. instructions consult detailed grounding Code. If additional information regarding needed, consult qualified electrician...
- Page 4 Add CAUTION block beginning terminals CAUTION.: The weld output we/ding cables when we/ding AMENDMENT TO SECTION 9- ENGINE MAINTENANCE Amend Section 9-3. GOVERNOR SERVICE Weld of this is 1850 speed engine Amend Section 9-4. CARBURETOR FLOAT SETTING Carburetor Change Effective With Serial No. HJ185451 I~1t~ bend, twist, apply...
- Page 5 Loosen the linkage & nuts Rotate thelinkage socket until the throttle rotation of the linkage socket rotation of the linkage socket be necessary adjust linkage & lock the of the position IMPORTANT Check the linkage ______________ socket linkage & nuts sockets &...
- Page 6 Tighten locking nuts by repeating Step 1~ Whenever the governor Whenever the governor speed (Step Amend Section 9-10. HIGH ALTITUDE Teledyne Walbro carburetor ft.). Minor adjustment will be necessary for proper is deemed necessary, Figure ment Loosen the main adjustment screw main adjustment...
- Page 7 Part No. Listed Replaced )tem Dia. In Parts List Mkgs. 010318 053724 017421 036259 025932 032 936 Page 032 936 Page 039 269 S2,5 053 359 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. With Part No. Description 015 602 VALVE,...
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Page 9: Table Of Contents
TABLE OF CONTENTS Section No. SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE SECTION 1 1 -1. Introduction General Precautions Welding Standards Booklet Index SECTION 2 INTRODUCTION 2-1. General Receiving-Handling Description 2-4. Safety SECTION INSTALLATION 3-1. Location 3-2. Connections Weld Output Equipment Grounding... - Page 10 Section No. SECTION GENERATOR MAINTENANCE 8-1. General 2. Collector Ring Brushes 8- 3. Welding Cables SECTION 9 ENGINE MAINTENANCE 9-1. Lubrication 9~ 2. Coolant System 9-3. Governor Service 9. 4. Carburetor Float Setting 9- 5. Vacuum Circuit Air Filter 9. 6. Idle Control Time Delay Adjustment 9- 7.
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Page 11: Introduction
SECTION 1-SAFETY RULES FOR 1-1. INTRODUCTION We learn by experience. Learning safety through experience, like child touching wasteful, and unwise. Let the experience Safe practices developed from experience cutting described in this manual. opment, and field experience have evolved reliable and safe installation, operation, servicing... - Page 12 This includes: thorough steam washing, depending solvent water solubility) followed purging carbon dioxide, using protective equipment mended A6.0. Waterfilling just substitute for inerting. A container with unknown contents above). Do NOT paragraph depend determine if it is safe weld cut. Hollow castings containers...
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Page 13: Arc Welding
Use pressure charts (available from your efficient, recommended pressure settings Check for leaks first pressurization after. Brush with soap solution (capful water). Bubbles indicate leak. Clean equivalent gallon off soapy after dried soap is combustible. water test; User Responsibilities Remove defective leaky equipment... -
Page 14: 4. Standards Booklet Index
Electrode Holders Fully insulated electrode holders should be used. Do NOT holders with protruding screws. Connectors Fully insulated lock-type connectors welding cable lengths. Cables Frequently inspect cables wear, IMMEDIATELY REPLACE those with damaged insulation avoid possibly bared cable. Cables with damaged resistance equivalent... -
Page 15: Introduction
Rated Welding Welding Amperes Current Coarse Ranges Output Range 65-140 @ 40V 45 To 100-220 100% Amps Duty Cycle 220 -475 GENERAL 2-1. This manual has been prepared especially izing with the design, installation, operation, personnel tenance, and troubleshooting of this equipment. -
Page 16: Installation
IMPORTANT Under this heading, installation, procedures practices tenance carefully followed result merit. 3-1) LOCATION (Figure A proper installation site should be selected for the the unit is provide dependable service, generator remain relatively maintenance free. F~O~TANT be mounted this welding generator (optional), that engine... -
Page 17: 3. Equipment Grounding Terminal
connections shown this figure for dc Straight polarity. Figure 3-2. Weld Output Connections Welding Cables welding cables ordered with this were listed should followed ensure performance: is recommended that the welding short possible, placed close adequate carrying capacity. current welding cables connections causes... -
Page 18: Engine Preparation
The FINE AMPERAGE control (full counterclockwise) position 120/240 volts plant being power voltage will vary in accordance 120/240 volts terminals. The voltage be determined from Figure 3-4. SECTION Manufacturers See the Engine manual complete engine care. 4-1. LUBRICATION This engine shippAd from the factory... -
Page 19: 4. Air Cleaner
NOTE If the does require battery ing, only required place step negative () operation connect negative terminal battery. Dry Charged Battery This shipped battery state. operation, it will be battery necessary lyte, proceed follows: protective clothing cover electrolyte solution. Remove the battery from unit and... -
Page 20: 120 Volts Ac Receptacle
SECTION 5-FUNCTION Fi~jre 5-1. Generator Controls 120 VOLTS AC RECEPTACLE Optional 240 Volts AC Receptacle, 3 kva of 120 volts 50/60 this duplex receptacle operating universal tools etc., when the power being operated weld rpm. voltage will decrease in accordance with output power the load... -
Page 21: 6. Duty Cycle
show minimum maximum curves When FINE AMPERAGE control range. will fall volt-ampere between curve maximum of the particular curves coarse 6. DUTY CYCLE (Figure duty cycle welding generator minute period that welding generator operated given output. This welding duty cycle. This percent means... -
Page 22: Volts Ac Duplex Receptacle
Remove VOLTS located front panel (see and allow free. hang Connect leads removed from RC1 duplex receptacle (one tacle). Install front panel. Affix supplied 240 VOLTS AC label VOLTS designation nameplate. Remove and retain jumper (see Figure 5-6). Move lead No. 3 (only lead terminal... -
Page 23: Sequence Of Operation
SECTION CAUTION ope~he Never under circumstances, of the with portion generator removed. addition open personnel, weather protection ponents of the unit will be greatly is void if the welding generator portion of the enclosure outer open EAr1 Make all electrical equipment sure 120 VOLTS AC... -
Page 24: Collector Ring Brushes
SECTION 8 CAUTION__.! If any work is be done spark plugs from the remove vent engine compression from catching repairpersons hand between the casting and the stationary adapter casting. negative I-) battery connect 8-1. GENERAL operation and trouble-free service of this weld/ Economical based generator... -
Page 25: Governor Service
9-3. GOVERNOR SERVICE speed setting sensitivity setting governor obtain weld rpm and Correct engine load conditions. The governor speed factory locked with lead seal. Do less absolutely necessary. NOTE The governor, used in conjunction does have Load Surge ,d~cribed in the Engine Manual. -
Page 26: Air Cleaner Service
The air intake cleaner is tube which allows the air be drawn either from the rounding engine compartment around the exhaust manifold of the prevent carburetor icing cold weather. Figure shows the selector operating position. When the tube remain about 1 from the air cleaner inlet. - Page 27 Figure 9-9. IDLE CONTROL/GOVERNOR LINKAGE ADJUST MENT (Figure 9-7) in the that proper idle and/or event engine being attained, perform following procedures engine for proper idle and weld rpm: Adjust length of the governor Figure 9-7) that the throttle stop 1/32 from the stop (3).
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Page 28: Key Type Ignition Switch Lubrication
rotation of the Screw rpm. Rotate the idle mixture clockwise until engine begins roll, then rotate wise until engine (11) Rotating screw flow, making Rotating (11) screw mits air, making more leaner. Connect motor vacuum unit the carburetor. motor vacuum Manually pivot vacuum (16) - Page 29 tMPORTANT engine exhaust system this welding been with equipped spark arrestor specifically ordered optional spark arrestor, maintained in effective mandatory this welding generator operated National Forest, grasslands, brush, forest covered land 4442 of California Public Resources Code). check local laws. areas, state your...
- Page 30 TROUBLE 120/240 No weld volts R EM 0 T E output 120/240 from volts CONTROL output terminals. VOLTS REMOTE RC1 Output receptacle ~S normal, remote connected Remote amperage AMPERAGE receptacle RC2. No output from 120/240.voltsac Fuse Fl terminals. Weld normal Output well from...
- Page 31 EQUIPMENT GROUND NOTE GROUND STRAP MUST RE INSTALLED RETWEEN ENGINE ERAME AND WELDER FRAME Figure NEUTRAL GROUNDING POWER DESIRED r~<CI CAUTION OWNERS REFER ATTEMPTING UOLTDGE P4RU. lh-< OPTIONDL 2ADVOLT INCLUDING RECEPTACLE LP GAS TOTAL TIME METER Circuit Diagram 1O~1. Circuit Diagram I3~ft45 ThERR4...
- Page 33 April 1978 FORM: OM-457C Effective With Serial No. HJ134589 PARTS LIST...
- Page 34 OM-457 Page Assembly Main Figure...
- Page 35 -I 0...
- Page 36 Item Dia. Factory Part No. Mkgs. Figure 017 430 010434 006698 018 858 602 938 010870 010 318 006 014 007 829 010 289 017 479 018 765 018 859 008698 010 433 *017 018 861 000 272 010 861 018 365 023 626 022 899...
- Page 37 Item Dia. Factory Mkgs. Part No. Figure Assembly (Contd.) Main R2,3 030 060 RESISTOR, 023892 CABLE,ground 007 894 MOUNT, engine 010266 SPRING,extension 017420 LATCH,door 004 444 UPRIGHT, base 000 553 MOUNT, dual stud 010 144 CLAMP, nylon 7/16 HOSE, neoprene 038 621 BLOCK, terminal 30...
- Page 38 Item Dia. Factory Mkgs. Part No. Figure 017 390 020 374 032 936 025 638 027 561 010 429 010 875 031 466 *Re~mmended Spare Parts. SURE TO PROVIDE STOCK. MODEL, Page Description Main Assembly (Contd.) BRACKET, tachometer mtg. BRACKET, tachometer engine mtg.
- Page 39 Item Dia. Factory Mkgs. Part No. Figure 025271 025517 025305 037 957 025 306 026 203 039 269 *012625 F1,2 039169 010493 059017 039207 032311 **003 024617 053390 035917 035776 025525 010021 018614 018665 600270 *020034 025321 025516 025305 037956 *Recommended Spare Parts.
- Page 40 Figure TC-006 071-A Figure Panel, Front Upper With Components Page...
- Page 41 Item Dia. Factory Part No. Mkgs. Figure 019 754 010 836 039 046 601 879 039044 601 880 039 045 039 043 601 976 010 528 059 343 059262 011 413 *605 S2,5 053 359 032 897 604 176 005 372 011 767 034876 039 047...
- Page 42 Factory Item Part No. 011 413 Figure 011 322 010 671 017 428 011 412 011 490 011 025 011 010 011 009 010 200 010 202 010 201 011 007 011 018 011 489 011 018 010 200 010 202 010 201 011 095 011 019...
- Page 43 Dia. Factory Item Mkgs. Part No. Figure 018 757 017 417 604 393 604 392 603 931 603 470 010 869 020 963 018 097 020 962 010 561 031 252 020 964 003 304 023 030 017 544 015 713 018 160 024 799 018 098...
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