Summary of Contents for Miller Trailblazer 302 Diesel
Page 1
Ma n u a l d o E q u i p a me n t o MI G MA G · T I G · A R C O S U B ME R S O · MU L T I P R OC E S S O · R E T I F I C A DOR A S C OR T E P L A S MA I N V E R S OR A S ·...
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage OM-217 454G - 2006−10, safety_rtm 3/06 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
STEAM AND HOT COOLANT can burn. TILTING OR TIPPING can cause injury. D If possible, check coolant level when engine is D Do not put any body part under unit while lifting. cold to avoid scalding. D Always use proper equipment (hoists, slings, D Always check coolant level at overflow tank, if chains, blocks, etc.) of adequate capacity to lift present on unit, instead of radiator.
SECTION 4 − INSTALLATION 4-1. 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-...
4-2. 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.
4-4. 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).
4-6. Overview And Engine Prestart Checks Generator Power Receptacles (see Radiator Cap 13 Oil Drain Section 6) Engine Maintenance Label (Inside Door) 14 Oil Dipstick Weld Output Terminals (see Section 4-7) Oil Fill Cap 15 Inline Fuel Strainer Operator Controls (see Section 5) 10 Thermostat Housing Plug 16 Air Cleaner Fuel Level Indicators...
Page 14
Engine must be cold and on a level sur- Y Engine shown with face. See maintenance label (Section 7-2) 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.
4-7. 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.
4-8. 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)
SECTION 5 − OPERATING THE WELDING GENERATOR 5-1. 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.
5-2. Weld Output Controls Ref. 216 171-B / Ref. 225 915-A Process/Contactor Switch If displays read: HLP_001, and engine does When a remote voltage/amperage control is not return to idle, check throttle solenoid. Turn connected to the Remote receptacle, the Auto See Section 5-3 for Process/Contactor switch Engine Control switch to OFF to reset shut- Sense Remote feature automatically switches...
5-3. Process/Contactor Switch Ref. 804 195-A / Ref 216 171 Process/Contactor Switch Stick Positions: vertical up joints or joints that do not require additional current for fit up inconsistencies. Y Weld output terminals are energized Use Stick positions for stick (SMAW) and when Process/Contactor switch is Stiff Arc (E6010) (Position 4) - This setting air carbon arc (CAC-A) cutting and...
5-4. 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.
5-6. Ending The TIG Arc With Auto-Cratert And Auto-Stopt Maintain shielding gas coverage and eliminate tungsten and work- piece contamination by using Auto-Crater or Auto-Stop to end the arc. Using Auto-Crater: Remote control is not needed when using Auto-Crater. Ending Arc Using Auto-Crater Lift torch slightly to start Auto- Crater end (current is re- duced).
5-7. Remote Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 4-9). 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.
SECTION 6 − OPERATING AUXILIARY EQUIPMENT 6-1. 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.
6-2. Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Full kVA Receptacle 240 V Full kVA Receptacle Amperes Amperes 1000 3500 5200 6700 8000 10,500 (Peak) 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.
Page 25
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 TM-217 454 Page 20 Trailblazer 302 D...
SECTION 7 − MAINTENANCE 7-1. 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...
7-2. Maintenance Label And Engine Maintenance Activities 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.
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.
7-4. 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 31
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 32
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...
7-5. Overload Protection Y Stop engine. When a circuit protector opens, it usually indicates a more seri- ous problem exists. Supplementary Protector CB4 (Located On Fuel Tank Cover) CB4 protects the stator winding supplying 24 volt ac output to Re- mote receptacle RC4.
Page 34
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
SECTION 8 − THEORY OF OPERATION Engine Supplies force to turn revolving Supplementary 24 V AC field. Protector Revolving Fields (Rotor) Turn at 3700 rpm maximum for weld and power. The speed and excita- 115 V AC Supplementary tion current of the field coils deter- Protector mine voltages in stator windings.
Page 36
12 Process/Contactor Switch (Located On PC2) Selects weld process and weld out- put on/off control (Remote or Elec- Process/Contactor trode Hot). Switch (Located On PC2) 13 Supplementary Protectors CB1, CB2, And CB3 Protect 120 V AC and 240 V AC re- Voltage Feedback ceptacles RC1, RC2, and RC3 Power...
SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting Tables See Sections 9-2 for test points and values and Section 14 and following for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. A. Welding Trouble Trouble Remedy No weld output;...
Page 38
Trouble Remedy Low weld output (continued). Check power board PC1 and connections, and replace if necessary (see Section 9-5). Check control board PC2 and connections, and replace if necessary (see Section 9-7). High weld output. Decrease V/A control setting. Check engine speed, and adjust if necessary (see Section 7-4). Check for obstructed movement of throttle solenoid TS1 linkage (see Section 7-4).
Page 39
Trouble Remedy Tungsten electrode oxidizing and not re- Check and tighten all gas fittings. maining bright after conclusion of weld. Increase postflow time. Shield weld zone from drafts. Use clean filler rod or material. Replace torch parts if water has leaked into torch. B.
Page 40
Trouble Remedy Check battery connections and tighten if necessary. Check plug PLG5 and plug PLG8 connections. Check continuity and connections of Engine Control switch S2. Repair or replace if necessary. Check engine charging and starting systems according to engine service manual. Engine cranks but does not start.
Page 41
Trouble Remedy Check air cleaner element. Clean or replace element as necessary (See Section 7-3). Readjust throttle linkage if necessary (see Section 7-4). Tune engine according to engine manual. Engine idles but does not reach weld Check solenoid linkage for obstructions, and readjust throttle linkage if necessary (see Section 7-4). speed.
Page 42
Trouble Remedy Check throttle solenoid TS1 for proper coil voltage and connections. Check continuity of coil and condition of contacts. Replace TS1 if necessary. Check power board PC1 and connections, and replace if necessary (see Section 9-6). LED5 and LED6 on PC1 light when PC1 is energized.
9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3) Test Equipment Needed: See Section 9-6 for PC1 data Wave form Throttle Glow Plug Solenoid TS1 Control (Pull-To-Idle) Relay CR3 Throttle Solenoid Control Relay CR2 V25, V24, V27, V26, Shutdown Control Relay...
Page 44
V15, R13 V5, R8 V18, R2 V14, V17, V16, V7, R9 V8, R10 V0, R11 V19, See Section 9-4 for waveforms A, B, C, D, E, F, G V1, V2 A, B, E, F C, D 231 579-A Trailblazer 302 D TM-217 454 Page 39...
9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2) Test Equipment Needed: Voltage Readings ± Tolerance − 10% unless specified ° ° Condition − 70 F (21 C); cold machine (no warm-up); Electrode Hot-Stick mode; no load; weld/power rpm unless noted Reference −...
Page 46
Amperage Readings ± Tolerance − 5% unless specified ° ° Condition − 70 F (21 C); cold machine (no warm-up); no load unless specified Process/Contactor switch in Electrode Hot − Stick mode Rotor Exciter Current: 4.35 amps dc (no load, idle rpm), 7.9 amps dc (no load weld/power rpm) 7.5 amps dc (25 volt, 200 amp stick weld load at weld/power rpm) 8.3 amps dc (5 kW generator power load at weld/power rpm)
9-4. Waveforms For Section 9-2 The waveforms represent the output of the welding power source. When operating properly, the power source waveforms match those shown here. 2 ms 20 V 2 ms 5 V A. DC/CC Mode, DC Open-Circuit Voltage B.
Page 48
2 ms 50 V 2 ms 50 V E. AC/CC Mode, AC Open-Circuit Voltage, F. AC/CC Mode, 25 Volts AC, 175 Amperes, (Resistive Load) 200 ms 1 V D. Pulse Width Modulation Signal Between Power Board PC1 And Control Board PC2 Test Equipment Needed: Trailblazer 302 D TM-217 454 Page 43...
9-5. Power Board PC1 Testing Information Be sure plugs are secure before testing. Use Section 9-6 for specific values during testing. Power Board PC1 LED Location Test Equipment Needed: 804 198-A / 223 913-A Trailblazer 302 D TM-217 454 Page 44...
9-6. Power Board PC1 Test Point Values Unless otherwise noted: a) Tolerance − +10% b) Reference − to circuit common (chassis) c) Readings taken at no load Voltage Readings Receptacle Value RC21 Generator Shutoff Signal (originates on PC1): 0 volts dc during normal operation, +15 volts dc during a fault condition Engine Speed Control: 0 volts dc (idle rpm), +14 volts dc (weld/power rpm) Battery voltage supplied to Control Board PC2 when Engine Control Switch S2 is on (engine does not...
Page 51
Receptacle Value RC26 Not used Reference for RC26−3 values Electrode Hot Stick mode (all settings): +45 volts dc (idle rpm), +18−29 volts dc (weld/power rpm) Electrode Hot Tig mode: +8.8 volts dc (idle rpm), +4.6 volts dc (weld/power rpm) Electrode Hot Mig mode, weld/power rpm: +17.4 volts dc maximum Voltage/Amperage control setting +3.7 volts dc minimum Voltage/Amperage control setting Electrode Hot Mig mode, idle rpm:...
9-7. Control Board PC2 Testing Information Be sure plugs are secure before testing. Use Section 9-8 for specific values during testing. Control Board PC2 Receptacle RC11 Receptacle RC12 Receptacle RC13 Receptacle RC14 Receptacle RC15 Receptacle RC16 Receptacle RC17 LED Location Typical receptacle configuration.
9-8. Control Board PC2 Test Point Values Unless otherwise noted: a) Tolerance − +10% b) Reference − to circuit common (chassis) c) Readings taken at no load Voltage Readings Receptacle Value RC11 Current transformer: 0 (zero) volts ac with no auxiliary power load, +3.6 volts ac with 100 watt light bulb plugged in Not used Reference for values at RC11−1...
Page 54
Receptacle Value RC15 (continued) Speed lock input: 0 volts dc when Speed Lock switch S7 is in idle, +5 volts dc when S7 is in weld/ power Circuit common Not used RC16 Generator shutoff (origin): 0 (zero) volts dc during normal operations, +15 volts dc during fault Not used Battery voltage when Engine Control switch S2 is on (engine does not have to be running) Zero cross signal (originates on Power Board PC1): +7.4 volts dc (idle rpm), +7.75 volts dc (weld/...
9-9. Replacing Brushes And Cleaning Slip Rings Y Stop engine and let cool. Endbell Brush Holder Assemblies Remove brush holder assemblies. Keep hardware for reinstallation. Do not remove brushes from hol- der. Replace brush holder assem- bly if brushes are damaged, or at or near minimum length.
9-10. Adjusting Wire (MIG) Weld Puddle Consistency (Units With Stabilizer Tabs) 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.
9-11. Checking Unit Output After Servicing Also use output waveforms to check unit output after servic- ing (see Section 9-4). Check engine speeds, and adjust if necessary (see Section 7-4). 120 Volt AC Receptacles RC2 And RC3 240 Volt AC Receptacle RC1 Check voltage at receptacles.
SECTION 10 − DISASSEMBLY AND REASSEMBLY 10-1. Disassembly Of Unit As an alternative to the complete dis- assembly procedure shown, the en- gine and rotor can be removed as one assembly from the engine end. Remove brush assemblies from endbell, support stator with blocks, and remove hardware holding stator to engine.
10-2. Disassembly Of Generator Stator Rotor Assembly Bearing Rotor Fan Engine Adapter Stud Brush Holder Assembly (One Of Two Assemblies Shown) Endbell Apply anti-seize com- pound (Loctite 76732) to all contacting surfaces be- tween rotor and engine. Apply SAE 30W oil to both ends of studs before installing.
SECTION 11 − ELECTRICAL DIAGRAMS The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside machine case or contact distributor for more information. The following is a list of all diagrams for models covered by this manual. Model Serial Or Style Number Circuit Diagram...
Page 61
Figure 11-1. Circuit Diagram For Welding Generator Eff w/LF314257 Thru LG095180 Trailblazer 302 D TM-217 454 Page 56...
Page 65
Table 11-1. Lead List Summary For Trailblazer 302 D Models Eff w/LG095181 And Following Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram). Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied grease had been present.
SECTION 12 − RUN-IN AND WETSTACKING run_in_D722 9/05 12-1. 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.
SECTION 13 − PERFORMANCE DATA 13-1. Fuel Consumption Curves On a typical job using 1/8 in 7018 Weld Fuel Consumption electrodes (125 amps, 20% duty 2.00 cycle), expect about 24 hours of op- eration. 1.75 Welding at 150 amps at 40% duty cycle uses approximately 1/2 gal- lon per hour, or about 22 hours of 1.50...
13-2. 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 13-3. 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.
13-4. 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 TM-217 454 Page 64 Trailblazer 302 D...
13-5. 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 Trailblazer 302 D...
13-6. 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 TM-217 454 Page 66 Trailblazer 302 D...
Page 72
2006−11 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding TIG (GTAW) Welding Description Engine Driven Welding Generator Trailblazer 302 Diesel ™ Eff w/LF314257 And Following For OM-217 454 Revisions A Thru G Visit our website at www.MillerWelds.com...
....228434 Cover, Top Service Assy Trailblazer 302 Diesel (Includes) .......
Page 74
Eff w/LF314257 And Following Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly (Continued) ....221986 Door, Access Engine Side LH ........
Page 75
Eff w/LF314257 And Following Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly (Continued) ....212975 Panel, Rear ........... . .
Page 76
Eff w/LF314257 And Following Item Part Description Quantity Figure 14-2. Generator (Figure 14-1 Item 29) ....227724 Label, Warning Moving Parts Can Cause Serious Etc .
Page 77
Eff w/LF314257 And Following Hardware is common and not available unless listed. 804 202-A Figure 14-3. Panel, Front w/Components TM-217 454 Page 72 Trailblazer 302 D...
Page 78
Eff w/LF314257 And Following Item Dia. Part Mkgs. Description Quantity Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 69) ......Nameplate (Order By Model &...
Page 79
Eff w/LF314257 And Following Note Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs. Description Quantity Wiring Harnesses .