Miller Trailblazer 251- Manuals

Miller Trailblazer 251– User Manual in PDF format online.

Manuals:

User Manual

User Manual Miller Trailblazer 251

Summary

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - WARNING; TABLE OF CONTENTS

The following terms areused interchangeablythroughout this manual:MIG = GMAW, Wire WeldingTIG = GTAWStick = SMAW The engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive harm. WARNING TABLE OF CONTENTS SECTION 1 – SAFETY...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.

OM-485 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This grou...

Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.

OM-485 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ove...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance; TILTING OF TRAILER can cause injury.

OM-485 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting as ne...

Page 8 - Principal Safety Standards

OM-485 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qualif...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-485 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message d...

Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur

OM-485 Page 6 tous les métaux renfermant ces éléments peuvent dégager des fuméestoxiques en cas de soudage. Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La pro...

Page 11 - LIRE LES INSTRUCTIONS.

OM-485 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branch...

Page 13 - SECTION 2 – DEFINITIONS; Symbol Definitions; SECTION 3 – SPECIFICATIONS

OM-485 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil On Check Valve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire Stick (SMA...

Page 14 - Dimensions, Weights, And Operating Angles; Fuel Consumption

OM-485 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 31 in (787 mm) A B Width 18-3/4 in (476 mm) B C Depth 46 in (1164 mm) Do not exceed operating angles whilerunning or engine damage will occur. A 18 in (457 mm) D G Do not move or operate unit where itcould tip. B 16-1/2 ...

Page 15 - Auxiliary Power Curve; Duty Cycle

OM-485 Page 11 SA-183 654 The ac auxiliary power curveshows the auxiliary power availablein amperes at the receptacles. 3-4. Auxiliary Power Curve Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and voidwarranty. 100%...

Page 17 - SECTION 4 – INSTALLATION; Installing Welding Generator

OM-485 Page 13 SECTION 4 – INSTALLATION install1 1/97 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment GroundingTerminal 4 Grounding Cable Use #10 AWG or larger insulatedcopper wire. If unit does not have GFCI re-ceptacles, use GFCI-pro...

Page 19 - Selecting Weld Cable Sizes; Remote 14 Receptacle Information

OM-485 Page 15 4-5. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 1...

Page 20 - Adjusting MIG Weld Puddle Consistency

OM-485 Page 16 4-7. Adjusting MIG Weld Puddle Consistency ST-801 537-B / Ref. ST-180 601-F Stop engine. Stabilizer DC-Z is factoryconnected to suit most MIG (WireWelding) applications. To change MIG weld puddle consis-tency, proceed as follows: Remove lower front panel and sidepanel. Starting from c...

Page 21 - SECTION 5 – OPERATING WELDING GENERATOR; Front Panel Controls

OM-485 Page 17 SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls Ref. ST-180 601-F 1 DC Polarity/AC Switch Use switch to select AC weld output or polarityof DC weld output. Do not switch under load. 2 Process Select Switch Use switch to select output for weld process. Do not switch u...

Page 22 - Remote Amperage/Voltage Control

OM-485 Page 18 5-2. Remote Amperage/Voltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control toRC1 (see 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...

Page 23 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Auxiliary Power Receptacles And Circuit Breakers

OM-485 Page 19 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Use GFCI-protected exten-sion cords. 1 120 V 15 A AC DuplexReceptacle RC1 2 240 V 15 A AC DuplexReceptacle RC2 RC1 and RC2 supply 60 Hz single-phase power at weld/power speed.Maximum output...

Page 24 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance

OM-485 Page 20 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Stop engine before maintaining. See also Engine Manual andmaintenance label. Service engine moreoften if used in severe conditions. Recycle engine fluids. 8 h Wipe up spills. Check fluid levels.See Section 4-2. OILFu...

Page 25 - Maintenance Label

OM-485 Page 21 7-2. Maintenance Label ONAN P216/P220 GAS ENGINE Check + S-165 623-E daily. Optional Gasoline ° C +30 +20 +10 0 -10 -20 -30 ° F Spark Arrestor Inspection And Service 20 operating hours - . . see Owner’s Manual Fuel Grade Regular or Unleaded . . . . . . . . . Fuel Filter MILLER 066 113...

Page 26 - Servicing Air Cleaner; Servicing Optional Spark Arrestor

OM-485 Page 22 7-3. Servicing Air Cleaner aircleaner3 1/97 – ST-156 852 / Ref. ST-180 601-F / S-0759 Stop engine. Do not run engine without aircleaner or with dirty element. 1 Wrapper (Foam Element) Wash wrapper with soap and watersolution. Allow wrapper to air drycompletely. Spread 1 tablespoon SAE...

Page 27 - Changing Engine Oil, Oil Filter, And Fuel Filter

OM-485 Page 23 7-5. Changing Engine Oil, Oil Filter, And Fuel Filter Ref. ST-801 532-B / ST-800 395-A / Ref. ST-180 601-F / S-0842 Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord-ing to engine manual. Close valve and valve capbefore ...

Page 28 - Adjusting Engine Speed

OM-485 Page 24 7-6. Adjusting Engine Speed Ref. ST-801 532-B / ST-800 397 After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows: Start engine and run until warm.Turn A/V control to max. Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting Screw L...

Page 29 - Overload Protection

OM-485 Page 25 Stop engine. If circuit breaker or fusecontinues to open, contactFactory Authorized ServiceAgent. 1 Circuit Breaker CB1 CB1 protects the 115 volt ac outputto Remote 14 receptacle RC1. IfCB1 opens, 115 volt ac output toRC1 stops. 2 Circuit Breaker CB2 CB2 protects the 24 volt ac output...

Page 32 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram for Welding Generator

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

Page 33 - SECTION 9 – AUXILIARY POWER GUIDELINES; Selecting Equipment; Grounding Generator To Truck Or Trailer Frame; OR

OM-485 Page 29 SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment aux_pwr 12/96 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this s...

Page 34 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?

OM-485 Page 30 9-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 Us...

Page 36 - Approximate Power Requirements For Contractor Equipment

OM-485 Page 32 9-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...

Page 37 - Power Required To Start Motor; How Much Power Can Generator Supply?

OM-485 Page 33 9-8. Power Required To Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table tofind kVA/HP. If code is not listed,multiply running amperage by six tofind starting amperage. Step 2: Find Motor HP a...

Page 38 - -10. Typical Connections To Supply Standby Power

OM-485 Page 34 9-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection. 4...

Page 40 - SECTION 10 – PARTS LIST

OM-485 Page 36 SECTION 10 – PARTS LIST ST-801 613-C Hardware is common andnot 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 Fig 10 – 2 44 Figure 10-1. Main Assembly

Page 47 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 48 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...