Miller-electric Trailblazer DC User Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW)Engine Driven Welding Generator(AC Available On AC/DC Mod

OM-4407 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4407 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4407 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4407 Page 9SECTION 3 − DEFINITIONS3-1. Symbol DefinitionsStop EngineFast(Run, Weld/Power)Fast/Slow(Run/Idle)Slow (Idle)Start Engine Panel/Local Tem

OM-4407 Page 10SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeRatedWeldingOutputMaximumOpen-CircuitVoltageAmperageRan

OM-4407 Page 11IDLE − KOHLER AND ROBINROBIN4-3. Fuel Consumption While Welding050100 150 200 250 300DC WELD AMPERES AT 100% DUTY CYCLEKOHLER0.000.250.

OM-4407 Page 12Ref. 204 922The ac generator power curveshows the generator power avail-able in amperes at the receptacles.4-5. Generator Power Curve05

OM-4407 Page 13204 923 / 204 928 / 204 935The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding gen

OM-4407 Page 14204 934 / 204 930The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Cu

OM-4407 Page 15SECTION 5 − INSTALLATIONinstall2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Do not weld on base. Weldingon base can cause fuel tan

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4407 Page 165-2. Engine Prestart Checks (Robin EH64-Powered Units)803 098 / 800 392-JFullFullGasolineCheck all fluids daily. Engine must becold and

OM-4407 Page 175-3. Engine Prestart Checks (Kohler-Powered Units) 801 221 / 802 849-AFullCheck all fluids daily. Engine must becold and on a level sur

OM-4407 Page 185-4. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber

OM-4407 Page 195-5. Connecting The BatteryRef. 800 394-C / Ref. 206 422 / Ref. S-0756-D+−3/8, 1/2 in Connect negative (−)cable last.Tools Needed:5-6.

OM-4407 Page 205-7. Connecting To Weld Output Terminals Stop engine. Do not connect to CC and CVterminals at the same time.AC/DC Models:1 Work Weld

OM-4407 Page 215-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4407 Page 225-10. Adjusting Wire (MIG) Weld Puddle Consistency803 0993/8, 7/16 inTools Needed:132 Stop engine and let cool.Stabilizer DC-Z is fact

OM-4407 Page 23SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls1 Process/Contactor SwitchSee Section 6-2 for Process/Contactorswitch i

OM-4407 Page 246-2. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswi

OM-4407 Page 256-3. Remote Amperage/Voltage Control1 Remote Receptacle RC4Connect optional remote control toRC4 (see Section 5-9).2 Remote Hand Contro

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-4407 Page 26SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles And Circuit BreakersRef. 206 4221253 If unit does not have G

OM-4407 Page 277-2. Optional Generator Power Receptacles If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Generator power

OM-4407 Page 287-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)plug1 11/03 − 120 813-DThe plug can be wired for a 240 V

OM-4407 Page 29SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS)8-1. Maintenance Label (Robin EH64-Powered Units)

OM-4407 Page 308-2. Routine Maintenance (Robin EH64-Powered Units)Follow the storage procedure in the engine owner’s manual if the unit will not be us

OM-4407 Page 31Every 200 hReplace fuelfilter. SeeSection 8-6.Change oil filter. SeeSection 8-6 andmaintenance label.Checksparkplugs.Replaceunreadablel

OM-4407 Page 328-3. Servicing Air Cleaner (Robin EH64-Powered Units) aircleaner5 1/97 − 803 070 / Ref. 200 017 / S-0759 Stop engine. Do not run engi

OM-4407 Page 33 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedServ

OM-4407 Page 348-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units)803 098 / S-0842 Stop engine and let cool.1 Oil Drain

OM-4407 Page 358-7. Adjusting Engine Speed (Robin EH64-Powered Units)803 098After tuning engine, check enginespeeds with a tachometer (seetable). If n

TABLE OF CONTENTSSECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Ma

OM-4407 Page 36SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS)9-1. Routine Maintenance (Kohler-Powered Units)Recycleenginefluids. Stop engine before m

OM-4407 Page 379-2. Maintenance Label (Kohler-Powered Units)Follow the storage procedure in the engine owner’s manual if the unit will not beused for

OM-4407 Page 389-3. Servicing Air Cleaner (Kohler-Powered Units) aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759 Stop engine. Do not run engine

OM-4407 Page 399-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)802 849-A / S-0842 Stop engine and let cool.1 Oil Drain Va

OM-4407 Page 409-6. Adjusting Engine Speed (Kohler-Powered Units)802 849-A / 801 209-AAfter tuning engine, check enginespeeds with a tachometer (seeta

OM-4407 Page 41 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedServ

OM-4407 Page 42SECTION 10 − TROUBLESHOOTING10-1. Welding TroubleshootingTrouble RemedyNo weld output. Check control settings.Check weld connections.Di

OM-4407 Page 43Trouble RemedyLack of high frequency; difficulty inestablishing Gas Tungsten Arc Weld-ing arc.Use proper size tungsten for welding ampe

OM-4407 Page 44Trouble RemedyEngine does not start. Check fuel level (see Section 5-2 or 5-3).Check battery and replace if necessary.Check engine char

OM-4407 Page 45NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-4407 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow thes

OM-4407 Page 46SECTION 11 − ELECTRICAL DIAGRAMSFigure 11-1. Circuit Diagram For Welding Generator Models With AC/DC Output

OM-4407 Page 47 209 625-C

OM-4407 Page 48Figure 11-2. Circuit Diagram For Welding Generator Models With DC Output Only (Kohler Only)

OM-4407 Page 49209 620-B

OM-4407 Page 50SECTION 12 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4407 Page 5112-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4407 Page 5212-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4407 Page 5312-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4407 Page 5412-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4407 Page 5512-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4407 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4407 Page 5612-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4407 Page 57Notes

OM-4407 Page 58SECTION 13 − PARTS LIST802 951 Hardware is common andnot available unless listed.12345678911141617102827262529303134361837405657−Fig.1

OM-4407 Page 59DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 182367 Panel, Side Rh 1. . . . . . . . . . . . . . . . . . .

OM-4407 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity25 168385 Label, Warning Battery Explosion Can Blind 1

OM-4407 Page 61DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity206537 Harness, Wrg Ignition (includes) 1. . . . . . .

OM-4407 Page 62802 952 Hardware is common andnot available unless listed.156710811121314181920212224252728293031333615263223324161734359Figure 13-2.

OM-4407 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Panel, Front w/Components (Figure 13-1 Item 57)Quantity1 206854 Panel, Front 1. . . .

OM-4407 Page 64DescriptionPartNo.ItemNo.Figure 13-3. Generator (Figure 13-1 Item 19)Quantity1 +206 406 Stator, Generator 1. . . . . . . . . . . . .

OM-4407 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 3/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4407 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4407 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez