Miller Trailblazer 300D NT Owner's Manual
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Miller Trailblazer 300D NT Owner's Manual

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Trailblazer 300D NT
OM-487
January 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Engine Driven Welding Generator
R
187 558M

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Summary of Contents for Miller Trailblazer 300D NT

  • Page 1 OM-487 187 558M January 2001 Processes MIG (GMAW) Welding Flux Cored (FCAW) Stick (SMAW) Welding TIG (GTAW) Welding Description Engine Driven Welding Generator Trailblazer 300D NT Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. Symbol Usage .

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    READ INSTRUCTIONS. stopping engine. D Do not let low voltage and frequency caused by D Use only genuine MILLER replacement parts. low engine speed damage electric motors. D Perform engine maintenance and service D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle according to this manual and the engine where applicable.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment D Have only qualified persons familiar with such as robots.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • 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 Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer D Porter des gants et des vêtements de protection pour leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Battery (Engine) Clearance Read Operator’s Engine Amperes Volts Manual MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire Alternating Current...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 33-1/2 in (851 mm) Width 18-3/4 in (476 mm) Y Do not exceed tilt angles or engine could Depth 48 in (1219 mm) be damaged or unit could tip. Y Do not move or operate unit where it could 18 in (457 mm) tip.

  • Page 15: Auxiliary Power Curve

    3-4. Auxiliary Power Curve The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. AC POWER AMPERES AT 120V AC POWER AMPERES AT 240V ST-189 268 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated 100% Duty Cycle at 290 Amperes DC load without overheating.

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/AC Mode the welding generator. Curves of other settings fall between the curves shown. AC AMPERES B. CC/DC Mode DC AMPERES C. CV/DC Mode DC AMPERES ST-189 278 / ST-189 280 / ST-189 282-A OM-487 Page 12...

  • Page 17: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- Movement Airflow Clearance vided in base. Y Do not lift unit from end. 18 in Y Always securely...

  • Page 18: Engine Prestart Checks

    4-3. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure is low or engine tem- perature is high. Check radiator coolant This unit has a low oil pressure shut- level when fluid is low in down switch.

  • Page 19: Adding Coolant To Radiator

    4-4. Adding Coolant To Radiator Y Stop engine and let cool. Check coolant level according to Section 4-3 before starting Full this procedure. If coolant level is below bottom of radiator filler neck, add coolant as follows: Capacity: w/Overflow Tank 6.9 qt (6.5 L) Thermostat Housing Plug Remove thermostat housing plug.

  • Page 20: Selecting Weld Cable Sizes

    4-7. 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 21: Adjusting Mig Weld Puddle Consistency

    4-9. Adjusting MIG Weld Puddle Consistency Y Stop engine. Stabilizer DC-Z factory connected to suit most MIG (Wire Welding) applications. To change MIG weld puddle consis- tency, proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three leads 79 will be referred to as inner, middle, and outer.

  • Page 22: Section 5 - Operating Welding Generator

    SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls Glow Plug Time ° ° F (21 ° ° 10 s F (0 ° ° 20 s –4 F (–20 Ref. ST-187 602-A DC Polarity/AC Switch If necessary, push switch up before start-up If the engine does not start, let the engine (see table above).

  • Page 23: Remote Amperage/Voltage Control

    5-2. Remote Amperage/Voltage Control Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). Remote Hand Control (Optional) Remote Foot Control (Optional) Engine runs at weld/power speed whenever a device con- nected to the remote 14 recep- tacle is running.

  • Page 24: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. 240 V 50 A AC Receptacle RC1 supplies 60 Hz single-phase power at weld/power speed.

  • Page 25: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Combined output of all receptacles limited to 8 kVA/kW rating of the generator. GFCI Receptacle Option 120 V 15 A AC GFCI Recep- tacles GFCI2 and GFCI3 GFCI2 and GFCI3 supply 60 Hz...

  • Page 26: Wiring Optional 240 Volt Plug

    6-3. Wiring Optional 240 Volt Plug 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 Each 120 V Duplex...

  • Page 27: Section 7 - Maintenance And Troubleshooting

    SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Maintenance Label OM-487 Page 23...

  • Page 28: Routine Maintenance

    7-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be NOTE used for an extended period. Y Stop engine before maintaining. also Engine Manual Recycle engine maintenance label. Service engine more fluids. often if used in severe conditions.
  • Page 29 200 h Replace primary Check radiator fuel filter. See hoses Section 7-6. clamps. Replace unreadable labels. 400 h Replace secondary fuel filter (see Section 7-6). 500 h Replace fan belt. Flush radiator. Service welding generator brushes and slip rings. Repair or replace Service more often in dirty cracked cables.

  • Page 30: Servicing Air Cleaner

    7-3. 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 31: Servicing Engine Cooling System

    7-4. Servicing Engine Cooling System Y Stop engine and let cool. Radiator Cap Radiator Drain Cock Drain engine coolant according to procedure in engine manual. Add engine coolant according to procedure in Section 4-4. 801 939 / 802 727 7-5. Servicing Optional Spark Arrestor Y Stop engine and let cool.

  • Page 32: Servicing Engine Fuel And Lubrication Systems

    7-6. Servicing Engine Fuel And Lubrication Systems Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine manual. Y Close valve and valve cap before adding oil and run- ning engine.

  • Page 33: Adjusting Engine Speed

    7-7. 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 34 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 35 C. Making Engine Speed Adjustments Before adjusting engine speed, verify throttle solenoid is installed properly (see Section B on previous page). ± 2450 100 rpm Check engine speeds with a tachometer Idle (see table). If necessary, adjust speeds as follows: 3750 Max Start engine and run until warm.

  • Page 36: Overload Protection

    7-8. Overload Protection Y Stop engine. Tools Needed: If a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized 3/8 in Service Agent. Circuit Breaker CB6 CB6 protects the 115 volt ac output to Remote 14 receptacle RC1.
  • Page 37 Trouble Remedy Low weld output. Check control settings. Place Remote Amperage/Voltage switch in Panel position, or move switch to Remote 14 position and connect remote amperage/voltage control to Remote 14 receptacle RC1 (see Section 4-8). Check and clean air cleaner as necessary (see Section 7-3). Check engine speed, and adjust if necessary (see Section 7-7).
  • Page 38 B. Auxiliary Power Trouble Remedy No power output. Reset circuit breakers CB1, CB2, CB3 and/or CB4 (see Section 6-1). Check fuse F1, and replace if necessary (see Section 7-8). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. Low power output.
  • Page 39 Trouble Remedy Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator according to engine manual. Engine does not return to idle speed. Be sure Engine Control switch S2 is in Run/Idle position.

  • Page 40: Section 8 - Electrical Diagram

    SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator OM-487 Page 36...
  • Page 41 201 926 OM-487 Page 37...

  • Page 42: Section 9 - Run-In Procedure

    SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking Welding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output. Do not idle engine longer than necessary.

  • Page 43: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxiliary power receptacle.

  • Page 44: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output. Turn Off grid. Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini-...

  • Page 45: Section 10 - Auxiliary Power Guidelines

    SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 10-2.
  • Page 46 10-3. 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 47 10-5. 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 48 10-7. 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 49 10-8. 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 50 10-10. Typical Connections To Supply Standby Power Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or Customer-supplied equipment is required if greater than the branch overcurrent generator is to supply standby power during protection.
  • Page 51 10-11. 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 52: Section 11 - Parts List

    SECTION 11 – PARTS LIST ST-802 106-B Figure 11-1. Main Assembly OM-487 Page 48...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ....182 367 PANEL, right side ..........
  • Page 54 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly (Continued) ....134 835 ..HOSE, sae .312 ID x .560 OD (order by ft) .
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly (Continued) ....180 628 PANEL, lower front ..........
  • Page 56 Hardware is common and not available unless listed. ST-802 107-B Figure 11-2. Panel, Front w/Components OM-487 Page 52...
  • Page 57 Item Dia. Part Mkgs. Description Quantity Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 80) ....187 593 PANEL, front ........... .
  • Page 58 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Generator (Fig 11-1 Item 56) ....+187 500 STATOR ............
  • Page 59 Effective January 1, 2000 (Equipment with a serial number preface of “LA” 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 APT, ZIPCUT &...

  • Page 60: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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