OM-486 187 236H February 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Stick (SMAW) Welding TIG (GTAW) Welding Description Engine Driven Welding Generator Trailblazer 251 NT Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal.
MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (–) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts.
H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie.
DES ORGANES MOBILES peuvent provoquer des blessures. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LE SOUDAGE À L’ARC risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.
SECTION 2 – DEFINITIONS 2-1.
3-2. Dimensions, Weights, and Operating Angles Dimensions Height 33 in (838 mm) Width 18-3/4 in (476 mm) Depth 45-1/2 in (1156 mm) A 18 in (457 mm) B 16-1/2 in (419 mm) C 3/4 in (19 mm) A B C Do not exceed tilt angles or engine could be damaged or unit could tip. D Do not move or operate unit where it could tip. G 4 Holes E F D 3-1/8 in (79 mm) E 32-3/4 in (832 mm) F 45-1/2 in (1156 mm) G 13/32 in (10 mm) Dia.
AC POWER VOLTS 3-4. Auxiliary Power Curve 280 140 240 120 200 100 160 80 120 60 80 40 40 20 0 0 The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. 0 20 40 60 80 100 120 140 160 60 70 80 AC POWER AMPERES AT 120V 0 10 20 30 40 50 AC POWER AMPERES AT 240V ST-189 268 3-5. Duty Cycle 100% Duty Cycle at 250 Amperes DC Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.
3-6. Volt-Ampere Curves 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/DC Mode 80 70 60 MAX DC VOLTS 50 40 30 MIN 20 10 0 0 50 100 150 200 250 300 350 DC AMPERES B. CV/DC Mode 50 DC VOLTS 40 30 MAX 20 MIN 10 0 0 100 200 300 400 500 600 DC AMPERES C.
SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Airflow Clearance Do not lift unit from end. 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR 1 2 3 18 in (460 mm) 18 in (460 mm) Grounding Location Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 4 Use #10 AWG or larger insulated copper wire.
4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 5 4 1 2 3 4 5 Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). 3 Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
4-4. Connecting The Battery Connect negative (–) cable last. + – Tools Needed: 3/8, 1/2 in Ref. ST-800 394-C / Ref. ST-189 925-A / Ref. S-0756-D 4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: 1/2 in ST-801 681 / Ref. ST-189 925-A 4-6. Connecting To Weld Output Terminals Do not connect to CC and CV terminals at the same time.
4-7.
4-9. Adjusting MIG Weld Puddle Consistency Stop engine. Stabilizer DC-Z is factory connected to suit most MIG (Wire Welding) applications. To change MIG weld puddle consistency, proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three leads 79 will be referred to as inner, middle, and outer.
SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls 1 2 3 8 1 runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs at weld/power speed. Use switch to select AC weld output or polarity of DC weld output. Place switch in Run position to operate most GMAW equipment. Process Select Switch 5 6 7 Do not switch under load. 2 DC Polarity/AC Switch 4 To Stop: turn Engine Control switch to Off position.
5-2. Remote Amperage/Voltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). 2 3 Remote Hand Control (Optional) Remote Foot Control (Optional) Engine runs at weld/power speed whenever a device connected to the remote 14 receptacle is running.
SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers If unit does not have GFCI receptacles, use GFCIprotected extension cord. Auxiliary 5 4 6 power decreases as weld current increases. 1 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 8 kVA/kW. 1 2 120 V 20 A AC Duplex Receptacle RC2 3 120 V 20 A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz singlephase power at weld/power speed.
6-2. Optional Auxiliary Power Receptacles If unit does not have GFCI receptacles, use GFCIprotected extension cord. Auxiliary power decreases as weld current increases. 1 Combined output of all receptacles limited to 8 kVA/kW rating of the generator. GFCI Receptacle Option 1 120 V 15 A AC GFCI Receptacles GFCI2 and GFCI3 GFCI2 and GFCI3 supply 60 Hz single-phase power at weld/power speed. Maximum output from GFCI2 or GFCI3 is 2.4 kVA/kW.
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Stop engine before maintaining. Recycle engine fluids. See Engine Manual and Maintenance Label. Service more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8h Wipe up spills. Check fluid levels. See Section 4-2. OIL Full 20 h 25 h Check and clean spark arrestor screen. See Section 7-4. Service air filter wrapper (foam element). See Section 7-3. 50 h Clean and tighten weld terminals.
7-2. Maintenance Label NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.
7-3. Servicing Air Cleaner Stop engine. Do not run engine without air cleaner or with dirty element. 1 1 2 Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Wrapper (Foam Element) Spread 1 tablespoon SAE 30 oil evenly into wrapper. Squeeze out excess oil. 2 Element Replace element if damaged, dirty, or oily. oil aircleaner3 1/97 – ST-156 852 / Ref. ST-185 095-A / S-0759 7-4. Servicing Optional Spark Arrestor Stop engine and let cool.
7-5. Changing Engine Oil, Oil Filter, And Fuel Filter 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 according to engine manual. Close valve and valve cap before adding oil and running engine. Fill crankcase with new oil to full mark on dipstick (see Section 7-2). Full 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. Start engine, and check for fuel leaks.
7-6. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 ± 100 rpm 3700 ± 50 rpm 6 Start engine and run until warm. Turn A/V control to max. Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting Screw Loosen two mounting screws.
7-7. Overload Protection Stop engine. Tools Needed: When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 3/8 in 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote 14 receptacle RC1. If CB5 opens, 24 volt ac output to RC1 stops. 2 Circuit Breaker CB6 CB6 protects the 115 volt ac output to Remote 14 receptacle RC1. If CB6 opens, 115 volt ac output to RC1 stops. Press button to reset breaker.
Trouble Low weld output. Remedy Check control settings. Place Remote Amperage/Voltage switch in Panel position, or move switch to Remote 14 position and connect remote amperage/voltage control to Remote 14 receptacle RC1. Check and clean air cleaner as necessary (see Section 7-3). Check and adjust engine speed (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. See engine manual. High weld output. Check control settings.
B. Auxiliary Power Trouble No power output. Remedy Reset circuit breakers CB1, CB2, CB3 and/or CB4 (see Section 6-1). Check fuse F1, and replace if necessary (see Section 7-7). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. Low power output. Check and clean air cleaner as necessary. Check and adjust engine speed (see Section 7-6). See engine manual. High power output. Check and adjust engine speed (see Section 7-6). Erratic power output.
SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1.
ST-190 578-B OM-486 Page 31
SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment 1 2 3 Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment 1 2 3 Be sure equipment has this symbol and/or wording. OR aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 9-2. Grounding Generator To Truck Or Trailer Frame 1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire.
9-3. Grounding When Supplying Building Systems 1 1 2 2 GND/PE Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes. 2 3 ST-800 576-B 9-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.
9-5.
9-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec.
9-8. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage.
9-10. Typical Connections To Supply Standby Power 1 2 3 Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 4 1 240 V 120/240 Volt 60 Hz Three-Wire Service Circuit Breakers or Fused Disconnect Switch Obtain and install correct circuit breakers or switch.
9-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
9 18 8 7 11 10 22 21 19 6 23 20 5 14 4 17 13 16 12 15 Figure 10-1. Main Assembly 2 24–Fig 10–3 1 28 27 39 38 36 37 26 25 35 34 54 – Fig. 10-2 40 29 42 41 51 43 45 30 52 47 31 33 44 50 ST-802 048-D OM-486 Page 39 49 48 47 46 45 55 32 not available unless listed.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly . . . 1 . . . . . . . . . . . . . 182 367 . . PANEL, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . ♦185 352 . . PANEL, right side stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 182 366 . . PANEL, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Continued) . . . . . . . . . . RC1 . . . 174 824 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG1 . . . 174 823 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG3 . . . 135 275 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 54) . . . 1 . . . . . . . . . . . . . 187 593 . . . . . 2 . . . R3,VR1 . . 046 819 . . . . . 3 . . . . . S1 . . . . 187 190 . . . . . 4 . . . . . . . . . . . . . 187 189 . . . . . 5 . . . . . . . . . . . . . 030 080 . . . . . 6 . . . . . R1 . . . . 072 623 . . . . . 7 . . . . . S6 . . . . 088 409 . . . . . 8 . . . . PC1 . . . 184 731 . . . . . 9 . . . . PC4 . . . 147 554 . . . . . 10 . . . . . S4 . .
Item No. Part No. Description Quantity Figure 10-3. Generator (Fig 10-1 Item 24) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 . . . . . . . . . . . . +186 238 . . . . . . . . . . . . . 013 367 . . . . . . . . . . . . . 186 239 . . . . . . . . . . . . . 181 143 . . . . . . . . . . . . . 107 417 . . . . . . . . . . . . . 134 981 . . . . . . . . . . . . . 160 567 . . . . . . . . . . . . . 187 151 . . . . . . . . . . . . . 047 878 . . . . . . . . . . . .
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
