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Miller Electric 301 G, DC, Trailblazer DC Every 200 h, Every 500 h, Every 1000 h

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OM-4407 Page 31

Every 200 h

Replace fuel

filter. See

Section 8-6.

Change oil filter. See

Section 8-6 and

maintenance label.

Check

spark

plugs.

Replace

unreadable

labels.

Every 500 h

Repair or

replace cracked

cables.

Service welding generator

brushes and slip rings. Service

more often in dirty conditions.*

Check

valve

clearance.*

Every 1000 h

Blow out or

vacuum inside.

During heavy

service, clean

monthly.

Contents

Main Trailblazer 301 G Trailblazer DC From Miller to You Page TABLE OF CONTENTS OM-4407 Page 1 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-4407 Page 3 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-4407 Page 5 SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-4407 Page 7 LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Symbol Definitions Pros weld and cut safely. Read the safety rules at the beginning of this manual. SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, and Operating Angles 4-3. Fuel Consumption While Welding DC WELD AMPERES AT 100% DUTY CYCLE KW AT 100% DUTY CYCLE US GAL/HR. LITERS/HR. 4-5. Generator Power Curve 4-6. Duty Cycle 4-7. Stick And MIG Mode Volt-Ampere Curves 4-8. TIG Mode Volt-Ampere Curves SECTION 5 INSTALLATION 5-1. Installing Welding Generator 5-2. Engine Prestart Checks (Robin EH64-Powered Units) 5-3. Engine Prestart Checks (Kohler-Powered Units) 5-4. Activating The Dry Charge Battery (If Applicable) + 5-5. Connecting The Battery + 5-6. Installing Exhaust Pipe 5-7. Connecting To Weld Output Terminals 5-8. Selecting Weld Cable Sizes* 5-9. Remote Receptacle Information Engine runs at weld/power speed whenever a device connected to the remote receptacle is running. NOTE 5-10. Adjusting Wire (MIG) Weld Puddle Consistency SECTION 6 OPERATING WELDING GENERATOR 6-1. Front Panel Controls 6-2. Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings 6-3. Remote Amperage/Voltage Control (Stick Welding Only) A/V Control Adjust Remote Control Set V/A Adjust Switch Set SECTION 7 OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers Page 7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) Page 8-2. Routine Maintenance (Robin EH64-Powered Units) Note Every 8 h Every 20 h Every 25 h Every 50 h Every 100 h Every 200 h Every 500 h Every 1000 h 8-3. Servicing Air Cleaner (Robin EH64-Powered Units) 8-4. Servicing Optional Spark Arrestor (Robin EH64-Powered Units) Tools Needed: 8-5. Overload Protection (Robin EH64-Powered Units) 8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units) 8-7. Adjusting Engine Speed (Robin EH64-Powered Units) SECTION 9 MAINTENANCE (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units) Every 8 h Full Every 20 h Every 25 h Page 9-3. Servicing Air Cleaner (Kohler-Powered Units) 9-4. Servicing Optional Spark Arrestor (Kohler-Powered Units) 9-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) 9-6. Adjusting Engine Speed (Kohler-Powered Units) 9-7. Overload Protection (Kohler-Powered Units) SECTION 10 TROUBLESHOOTING 10-1. Welding Troubleshooting 10-2. Generator Power Troubleshooting 10-3. Engine Troubleshooting Page Page Page Page Page Page SECTION 12 GENERATOR POWER GUIDELINES NOTE 12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer Frame 12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? 12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home Equipment 12-7. Approximate Power Requirements For Contractor Equipment 12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply? 12-10. Typical Connections To Supply Standby Power Pros weld and cut safely. Read the safety rules at the beginning of this manual. 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Page SECTION 13 PARTS LIST Figure 13-1. Main Assembly (Kohler Engine Shown) Page Page Page Figure 13-2. Panel, Front w/Components Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2004 (Equipment with a serial number preface of LE or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record