Miller Electric Trailblazer DC, 301 G, DC manual Service, Support

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Warranty Questions?

Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

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.

Support

Need fast answers to the tough welding questions? Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1.5 Years Parts — 3 Years Labor

*Original main power rectifiers

*Inverters (input and output rectifiers only)

2.3 Years — Parts and Labor

*Induction Heating Coils and Blankets

*APT & SAF Model Plasma Cutting Torches

*Remote Controls

*Accessory Kits

*Replacement Parts (No labor)

*Spoolmate Spoolguns

*Canvas Covers

Miller’s True BlueLimited Warranty shall not apply to:

1.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.)

2.Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Supplies (Unless Otherwise Stated)

*Intellitig

*Maxstar 150

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor Unless Specified

*DS-2 Wire Feeder

*Motor Driven Guns (w/exception of Spoolmate Spoolguns)

*Process Controllers

*Positioners and Controllers

*Automatic Motion Devices

*RFCS Foot Controls

*Induction Heating Power Sources

*Water Coolant Systems

*Flowgauge and Flowmeter Regulators (No Labor)

*HF Units

*Grids

*Maxstar 85, 140

*Spot Welders

*Load Banks

*Arc Stud Power Sources & Arc Stud Guns

*Racks

*Running Gear/Trailers

*Plasma Cutting Torches (except APT & SAF Models)

*Field Options

(NOTE: Field options are covered under True Bluefor the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 3/04

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Contents Description OM-4407203 236UProcesses From Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoquer des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbol DefinitionsDimensions, Weights, and Operating Angles − SpecificationsWeld, Power, And Engine Specifications Fuel Consumption While Welding Fuel Consumption While Using Generator Power100% Duty Cycle at 280 Amperes DC Generator Power CurveExceeding duty cycle can damage unit and void warranty Duty CycleCV/DC MIG Mode Stick And MIG Mode Volt-Ampere CurvesCC/AC Stick Mode CC/DC Stick ModeCC/DC TIG Mode TIG Mode Volt-Ampere CurvesCC/AC TIG Mode Installing Welding Generator − InstallationOil Check Oil Fill Engine Prestart Checks Robin EH64-Powered UnitsOil Follow run-in procedure in engine manual Engine Prestart Checks Kohler-Powered UnitsCharger Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Read and follow all instrucConnect negative − cable last Connecting The BatteryInstalling Exhaust Pipe + −DC Only Models Connecting To Weld Output TerminalsStop engine AC/DC ModelsRemote Receptacle Information Selecting Weld Cable SizesFor wetter weld puddle for mild steel Adjusting Wire MIG Weld Puddle ConsistencyFront Panel Controls Do not switch under load− Operating Welding Generator Switch Setting Process Output On/Off Control Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings Remote Amperage/Voltage Control Set Adjust Remote Control Switch Stick Welding Only− Operating Auxiliary Equipment Generator Power Receptacles And Circuit BreakersGfci Receptacle Option Optional Generator Power ReceptaclesIf unit does not have Gfci re Ceptacles, use Gfci Receptacle Current Available in Amperes 240Maintenance Label Robin EH64-Powered Units − Maintenance Robin EH64-POWERED UnitsEvery 50 h Routine Maintenance Robin EH64-Powered UnitsEvery 8 h Every 20 h Every 25 hEvery 1000 h Every 200 hEvery 500 h Servicing Optional Spark Arrestor Robin EH64-Powered Units Servicing Air Cleaner Robin EH64-Powered UnitsTools Needed Overload Protection Robin EH64-Powered UnitsTions as necessary, and wipe up fuel Close valve and valve capBefore adding oil Running engineWeld/Power Speed Adjustment Adjusting Engine Speed Robin EH64-Powered UnitsIdle Speed Adjustment Stop engine before maintaining − Maintenance KOHLER-POWERED UnitsRoutine Maintenance Kohler-Powered Units Maintenance Label Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered Units Servicing Air Cleaner Kohler-Powered UnitsFull Tools Needed Adjusting Engine Speed Kohler-Powered Units Overload Protection Kohler-Powered Units Trouble Remedy − TroubleshootingWelding Troubleshooting Engine Troubleshooting Generator Power TroubleshootingIs on Work like a Pro − Electrical Diagrams 209 625-C OM-4407 209 620-B Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-4407 Main Assembly Kohler Engine Shown − Parts ListMain Assembly Dia Part Description Quantity Mkgs 206537 Panel, Front w/Components Panel, Front w/Components -1Item Generator -1Item Page Page Support ServiceMiller Electric Mfg. Co Owner’s Record