Miller Electric Trailblazer Pro 350 D Owner's Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorOM-4413 207 948DJuly 2003Trailblazer Pro 35

OM-4413 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-4413 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4413 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4413 Page 9SECTION 2 – DEFINITIONS2-1. Symbol DefinitionsStop EngineFast(Run, Weld/Power)Fast/Slow(Run/Idle)Slow (Idle)Start Engine Panel/Local Tem

OM-4413 Page 103-2. Dimensions, Weights, and Operating AnglesDimensionsABHeight36 in (914 mm)(to top of exhaust)BCWidth 24 in (610 mm)D Do not exceed

OM-4413 Page 116 Minutes Welding 4 Minutes Resting3-4. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated l

OM-4413 Page 123-6. CC Stick Volt-Ampere Curves 207 961 / 207 962Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities

OM-4413 Page 133-7. CC TIG Volt-Ampere Curves207 964 / 207 965Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of

OM-4413 Page 143-8. DC/CV MIG Volt-Ampere Curves 207 963Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of unit.

OM-4413 Page 15SECTION 4 – 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-4413 Page 164-2. Engine Prestart Checks803 1781/2 in(13 mm)FullDieselCheck all fluids daily. Engine must be coldand on a level surface. Unit is shi

OM-4413 Page 174-3. Adding Coolant To RadiatorRef. 803 178 Stop engine and let cool. Check coolant level accordingto Section 4-2 before startingthis

OM-4413 Page 184-5. Installing Exhaust Pipe802 173-C / Ref. 207 554-A Point exhaust pipe in desireddirection but always away fromfront panel and dire

OM-4413 Page 194-7. Connecting To Weld Output Terminals Do not connect to CC and CVterminals at the same time.1 Work Weld Output Terminal2 CC (Stick/

OM-4413 Page 204-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4413 Page 214-10. Guidelines For Installing Customer-Supplied Emergency Air Shutdown ValveA customer-supplied emergency air shutdownvalve can be in

OM-4413 Page 22SECTION 5 – OPERATING WELDING GENERATOR115-1. Controls (See Section 5-2)207 554-A / Ref. 803 17811413121067915 2 3 485

OM-4413 Page 235-2. Description Of Controls (See Section 5-1)Engine Lights1 Engine Temperature LightLight goes on and engine stops if engine tem-perat

OM-4413 Page 245-3. Process/Contactor Switch207 554-A / 803 1791 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactor

OM-4413 Page 255-4. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC4Connect optional remote control toRC4 (see Section 4-9).0774 / Ref. 207 5

The following terms areused interchangeablythroughout this manual:MIG = GMAW, Wire WeldingTIG = GTAWStick = SMAWTABLE OF CONTENTSSECTION 1 – SAFETY PR

OM-4413 Page 265-5. Recommendations For Extreme Cold Weather Operation For more information on operating in coldweather, contact the nearest Factory

OM-4413 Page 275-6. Typical Stick Welding Connections And Control Settings803 310 / 207 554-A / Ref. S-0653 Stop engine. This section provides gener

OM-4413 Page 285-7. Typical MIG Welding Connections And SettingsA. Solid Wire Applications803 268 / 207 554-A Stop engine. This section provides gen

OM-4413 Page 29B. Self-Shielded Flux Core Wire Applications803 268 / 207 554-A Stop engine. This section provides generalguidelines and may not suit

OM-4413 Page 305-8. Typical MIG Connections And Settings Using Weld Control And Spoolgun803 308 / 207 554-A Stop engine. This section provides gener

OM-4413 Page 315-9. Typical DC Scratch Start TIG Connections And Settings803 309 / 207 554-A Stop engine. This section provides general guide-lines

OM-4413 Page 325-10. Typical AC TIG (With High Frequency Unit) Connections And Settings803 121 / 207 554-A Stop engine. Turn Off HF Unit and welding

OM-4413 Page 335-11. Typical Carbon Arc Cutting (CAC-A) Connections And Settings803 310 / 207 554-A Stop engine. Breathing compressed air can causes

OM-4413 Page 34SECTION 6 – OPERATING AUXILIARY EQUIPMENT6-1. Generator Power Receptacles And Circuit BreakersRef. ST-207 554-A1 If unit does not have

OM-4413 Page 356-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)Plug1 7/99 – ST-120 813-DThe plug can be wired for a 240

TABLE OF CONTENTSSECTION 7 – MAINTENANCE AND TROUBLESHOOTING 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Maintenance Labe

OM-4413 Page 367-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.N

OM-4413 Page 37Every 500 hReplace fan belt.Flush radiator.Repair or replacecracked cables.Drain sludge fromfuel tank. SeeSection 7-5.FUELSLUDGEEvery 8

OM-4413 Page 387-4. Servicing Air Cleaneraircleaner1 5/02 – ST-153 929-B / ST-153 585 / Ref. 803 283 / Ref. S-0698-B Stop engine. Do not run engine

OM-4413 Page 397-5. Servicing Engine Lubrication And Fuel Systems Ref. 803 178 / Ref. 207 554-A / S-0842Tools Needed:433 Stop engine and let cool.1 O

OM-4413 Page 407-6. Servicing Engine Cooling System802 579-B / 803 178 / 802 581 Stop engine and let cool.1 Radiator Draincock2 Radiator Cap3 Radiato

OM-4413 Page 417-7. Replacing Throttle Solenoid TS1803 178 Stop engine, and let cool. Disconnect battery, negative(–) cable first.Remove right side

OM-4413 Page 427-8. Adjusting Engine Speed803 178After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas f

OM-4413 Page 43 Stop engine. When a circuit breaker opens,it usually indicates a more seri-ous problem exists. ContactFactory Authorized ServiceAgen

OM-4413 Page 447-10. TroubleshootingA. WeldingTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switc

OM-4413 Page 45Trouble RemedyMin or max CV weld output only. Check position of Voltage/Amperage Adjustment control and Voltage/Amperage Adjust switch

OM-4413 Page 1SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow thes

OM-4413 Page 46C. EngineTrouble RemedyEngine will not crank. Reset circuit breaker CB8 (see Section 7-9).Check battery voltage.Check battery connectio

OM-4413 Page 47Trouble RemedyEngine does not return to idle speedwhen load is removed with EngineControl switch in Run/Idle position.Remove all weld a

OM-4413 Page 48SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Welding Generator

OM-4413 Page 49208 872-A

OM-4413 Page 50SECTION 9 – RUN-IN PROCEDURErun_in4 8/019-1. Wetstacking21 Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4413 Page 519-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4413 Page 529-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

OM-4413 Page 53SECTION 10 – GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4413 Page 5410-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4413 Page 5510-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4413 Page 2BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or useapproved air-

OM-4413 Page 5610-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4413 Page 5710-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4413 Page 5810-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4413 Page 5910-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4413 Page 60SECTION 11 – PARTS LIST Hardware is common andnot available unless listed.1234678910111213141516171819202122 – Fig.11-3232427262528293

OM-4413 Page 6136 – Fig. 11-43739385440725556575859606162636465666768695270715351734174454342444647485049939594929190989796888985848683828180797876757

OM-4413 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 013367 Label, Warning Moving Parts Can Cause Serious Etc 1. . .

OM-4413 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity39 193624 Engine, Kubota Dsl Elec Dh905–mi–b (Consistin

OM-4413 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity88 200407 Strap, Fuel Tank 1. . . . . . . . . . . . .

OM-4413 Page 65NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your ProfessionalWelding

OM-4413 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely i

OM-4413 Page 66803 270 Hardware is common andnot available unless listed.412 356789101112131416178181920212223242526272829303132333435363738394041424

OM-4413 Page 67DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Panel, Front w/Components (Figure 11-1 Item 103)Quantity1 Nameplate (order by model and

OM-4413 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Panel, Front w/Components (Continued)Quantity209831 Receptacles, W/Leads (consisting of)

OM-4413 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Stabilizer/Rectifier/Control Box Assembly (Figure 11-1 Item 22)Quantity1 SR1 198514 Rect

OM-4413 Page 70DescriptionPartNo.ItemNo.Figure 11-4. Generator (Figure 11-1 Item 36)Quantity1 210438 Endbell (consisting of) 1. . . . . . . . . . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/03Your 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-4413 Page 4FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder withproper guard

OM-4413 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom_10_02fre Avertissement: Protégez vous et les autres des blessures – lisez