Miller Trailblazer 251, Owner'S Manual

Page 1: ...sses Description TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Engine Driven Welding Generator OM 485 181 594F November 1997 Trailblazer 251 Visit our website at www MillerWelds...

Page 2: ...alue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself agains...

Page 3: ...ECTION 3 SPECIFICATIONS 9 3 1 Weld Power And Engine Specifications 9 3 2 Dimensions Weights And Operating Angles 10 3 3 Fuel Consumption 10 3 4 Auxiliary Power Curve 11 3 5 Duty Cycle 11 3 6 Volt Ampe...

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Page 5: ...ace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grou...

Page 6: ...aintaining Wear protective gloves and clothing when working on a hot engine Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipme...

Page 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appa...

Page 10: ...lures graves Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains...

Page 11: ...enir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquem...

Page 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 13: ...switch while welding 14 Remote 14 Receptacle Work Connection Engine Choke Wire Feed Electrode Positive Electrode Negative SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Welding Mod...

Page 14: ...t exceed operating angles while running or engine damage will occur A 18 in 457 mm D G Do not move or operate unit where it could tip B 16 1 2 in 419 mm 4 Holes C 3 4 in 19 mm E D 3 1 8 in 79 mm F 25...

Page 15: ...le in amperes at the receptacles 3 4 Auxiliary Power Curve Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void...

Page 16: ...183 651 A 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 A CC AC Mode B CC...

Page 17: ...nd genera tor frame to vehicle frame by metal to metal contact GND PE 3 4 2 OR OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow Clearance Location Grounding Do n...

Page 18: ...not connect to CC and CV terminals at the same time 1 Work Weld Output Terminal 2 Stick TIG CC Weld Output Terminal 3 Wire CV Weld Output Terminal For MIG welding connect work cable to Work terminal a...

Page 19: ...drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm2 equivalent weld cable sizes S 0007 E 4 6 Remote 14 Receptacle Information Socket Socket Informat...

Page 20: ...tabilizer DC Z 2 Inner Lead 79 3 Middle Lead 79 4 Outer Lead 79 5 Wire CV Weld Output Terminal Middle lead 79 is connected to Wire CV weld terminal at the factory Disconnect middle lead 79 from termin...

Page 21: ...n Run position engine runs at weld power speed Place switch in Run position to operate most GMAW equipment 5 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and...

Page 22: ...Section 4 6 2 Remote Hand Control Optional 3 Remote Foot Control Optional ST 801 534 ST 180 601 F S 0769 S 0774 1 Process Stick SMAW In Example Set Polarity Switch 2 Max 160 A CC DC Min 40 A CC DC Max...

Page 23: ...Breaker CB5 And CB6 CB5 and CB6 protect RC2 from overload If CB5 or CB6 opens RC2 does not work 120 volts may still be present at RC2 If a circuit breaker continues to open contact Factory Authorized...

Page 24: ...pper foam element See Section 7 3 50 h Change oil See Section 7 5 and maintenance label Change oil filter See Section 7 5 and maintenance label Clean and tighten weld terminals Clean cooling system Se...

Page 25: ...064 617 Onan 140 2628 01 Air Filter Wrapper MILLER 065 653 Onan 140 1496 Spark Plug Gap 0 025 in 0 6 mm Spark Plug Champion RS17YX Preferred or RS14YC Use only resistor spark plugs and wires 0 50 100...

Page 26: ...r solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily oil 1 2 Stop engine and let...

Page 27: ...ne oil and filter accord ing to engine manual Close valve and valve cap before adding oil and run ning engine Fill crankcase with new oil to full mark on dipstick see Section 7 2 4 Fuel Filter 5 Fuel...

Page 28: ...ble Release governor arm Place Engine Control switch in Run Idle position 6 Carburetor Stop With solenoid energized slide sole noid until idle speed screw just touches carburetor stop Tighten solenoid...

Page 29: ...panel F1 protects the exciter excitation winding from overload If F1 opens weld and auxiliary power output stops Replace any open fuses Reinstall cover before operating unit 3 8 in ST 801 533 C Ref S...

Page 30: ...piece is clean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Check and adjust engine speed see Section 7 6 Have Factory Authorized Service Agent check brushes sl...

Page 31: ...al See engine manual Engine starts but stops when Engine Control switch returns to Run position Check oil level see Section 4 2 Check and refill crankcase with proper viscosity oil for operating tempe...

Page 32: ...OM 485 Page 28 SECTION 8 ELECTRICAL DIAGRAM SC 188 716 Figure 8 1 Circuit Diagram for Welding Generator...

Page 33: ...e Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 9 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Te...

Page 34: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 9 8 3 Rating Data Rating shows volts...

Page 35: ...me Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mil...

Page 36: ...6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 H...

Page 37: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 38: ...Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or...

Page 39: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 40: ...T 801 613 C Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 10 9 11 12 14 15 16 17 18 19 13 20 Fig 10 3 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 39 45 46 43...

Page 41: ...1 065 251 OIL FILTER 1 121 652 FILTER CLAMPS fuel 1 065 709 SPARK PLUG 2 20 Fig 10 3 GENERATOR 1 21 167 730 CABLE battery neg 29 00 lg 1 165 600 CABLE battery neg 18 50 lg 1 22 182 935 HOLD DOWN batte...

Page 42: ...g a precautionary label the label should also be ordered For Optional 043 051 Stainless Steel Dress Up Kit Recommended Spare Parts To maintain the factory original performance of your equipment use on...

Page 43: ...E str dx grd 2P3W 15A 125V 1 073 690 PLUG 2P3W 15A 125V 16 RC2 604 103 RECEPTACLE str dx grd 2P3W 15A 250V 1 025 234 PLUG 2P3W 15A 250V 17 S3 4 011 609 SWITCH tgl SPDT 15A 125V 2 18 182 870 CONTROL pu...

Page 44: ...3 047 878 BAR retaining brushholder 1 14 161 306 CAP brushholder 3 15 126 984 BRUSH w spring 3 16 005 614 HOLDER brush 3 17 153 297 ENDBELL consisting of 1 18 143 220 O RING 2 859 ID x 139CS 1 19 2T 3...

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Page 47: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 48: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...