Miller Electric Trailblazer 251 NT Owner's Manual
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Miller Electric Trailblazer 251 NT Owner's Manual

Miller Electric Trailblazer 251 NT Owner's Manual

Engine driven welding generator
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Trailblazer 251 NT
OM-486
February 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Engine Driven Welding Generator
R
187 236H

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Summary of Contents for Miller Electric Trailblazer 251 NT

  • Page 1 Trailblazer 251 NT Visit our website at www.MillerWelds.com OM-486 187 236H February 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Stick (SMAW) Welding TIG (GTAW) Welding Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION 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.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    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.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

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

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 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. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie 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.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D 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. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Start Engine Engine Oil Engine MIG (GMAW), Wire Positive Time Do not switch while welding Wire Feed SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Rated Maximum Welding Welding Open-Circuit Mode Output...

  • Page 14: Dimensions, Weights, And Operating Angles

    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) 18 in (457 mm) 16-1/2 in (419 mm) 3/4 in (19 mm) 3-1/8 in (79 mm) 32-3/4 in (832 mm) 45-1/2 in (1156 mm) 13/32 in (10 mm) Dia.

  • Page 15: Auxiliary Power Curve

    3-4. Auxiliary Power Curve AC POWER AMPERES AT 120V AC POWER AMPERES AT 240V 3-5. Duty Cycle 100% Duty Cycle at 250 Amperes DC Continuous Welding The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. ST-189 268 Duty cycle is the percentage of 10 minutes that unit can weld at rated...

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves A. CC/DC Mode B. CV/DC Mode C. CC/AC Mode OM-486 Page 12 DC AMPERES DC AMPERES AC AMPERES 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.

  • Page 17: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Y Do not lift unit from end. Grounding Location 4-2. Engine Prestart Checks 1/2 in (13 mm) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.

  • Page 18: Activating The Dry Charge Battery (If Applicable)

    4-3. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes OM-486 Page 14 – Remove battery from unit. 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...

  • Page 19: Connecting The Battery

    4-4. Connecting The Battery Tools Needed: 3/8, 1/2 in 4-5. Installing Exhaust Pipe Tools Needed: 1/2 in 4-6. Connecting To Weld Output Terminals Y Connect negative (–) cable last. Ref. ST-800 394-C / Ref. ST-189 925-A / Ref. S-0756-D Point exhaust pipe in desired direction.

  • Page 20: Selecting Weld Cable Sizes

    4-7. Selecting Weld Cable Sizes 100 ft (30 m) Or Less Welding Amperes Amperes 10 – 60% 60 – 100% Duty Duty Cycle Cycle *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 21: Adjusting Mig Weld Puddle Consistency

    4-9. Adjusting MIG Weld Puddle Consistency Tools Needed: 3/8, 7/16 in Y Stop engine. Stabilizer DC-Z factory connected to suit most MIG (Wire Welding) applications. To change MIG weld puddle consis- tency, proceed as follows: Remove lower front panel and side panel.

  • Page 22: Section 5 - Operating Welding Generator

    SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls DC Polarity/AC Switch Y Do not switch under load. Use switch to select AC weld output or polar- ity of DC weld output. Process Select Switch Y Do not switch under load. Use switch to select output for weld process.

  • Page 23: Remote Amperage/Voltage Control

    5-2. Remote Amperage/Voltage Control Set Polarity Switch Set Remote Control Switches Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). Remote Hand Control (Optional) Remote Foot Control (Optional) Engine runs at weld/power speed whenever a device con- nected to the remote 14 recep- tacle is running.

  • Page 24: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Simultaneous Welding And Auxiliary Power Weld Current Watts Amperes 3500 4260 5140 6700 8000 8000 8000 OM-486 Page 20 Output 120 V 240 V Receptacle Receptacle Amperes Amperes 15.5 62.4...

  • Page 25: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Simultaneous Welding And Auxiliary Power Output Weld Current Watts Amperes 3500 4260 5140 6700 8000 8000 8000 120 V 240 V Receptacle Receptacle Amperes Amperes 15.5 62.4 31.2 62.4 31.2 62.4 31.2 Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord.

  • Page 26: Section 7 - Maintenance And Troubleshooting

    SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Check fluid levels. See Section 4-2. 20 h Check and clean spark arrestor screen. See Section 7-4. Clean cooling system. See engine manual. Change oil. See Section 7-5 and maintenance label. Service air filter element.

  • Page 27: Maintenance Label

    7-2. Maintenance Label Follow the storage procedure in the engine owner’s manual if the unit will not be NOTE used for an extended period. OM-486 Page 23...

  • Page 28: Servicing Air Cleaner

    7-3. Servicing Air Cleaner 7-4. Servicing Optional Spark Arrestor Tools Needed: 1/4 in OM-486 Page 24 Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution.

  • Page 29: Changing Engine Oil, Oil Filter, And Fuel Filter

    7-5. Changing Engine Oil, Oil Filter, And Fuel Filter Tools Needed: Full Ref. ST-801 942-C / ST-800 395-B / Ref. ST-189 925-A / S-0842 Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine manual.

  • Page 30: Adjusting Engine Speed

    7-6. Adjusting Engine Speed OM-486 Page 26 2200 100 rpm 3700 Left Side Top View Tools Needed: 1/4, 3/8 in After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Turn A/V control to max.

  • Page 31: Overload Protection

    7-7. Overload Protection 7-8. Troubleshooting A. Welding Trouble No weld output. Check control settings. Check weld connections. Disconnect equipment from auxiliary power receptacles during start-up. Place Output (Contactor) switch in On position, or move switch to Remote 14 position and connect remote contactor to Remote 14 receptacle RC1 (see Sections 4-8 and 5-1).
  • Page 32 Trouble Low weld output. 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).
  • Page 33 B. Auxiliary Power Trouble No power output. 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.

  • Page 34: Section 8 - Electrical Diagram

    SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator OM-486 Page 30...
  • Page 35 ST-190 578-B OM-486 Page 31...

  • Page 36: Section 9 - Auxiliary Power Guidelines

    SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment 9-2. Grounding Generator To Truck Or Trailer Frame OM-486 Page 32 Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles –...

  • Page 37: Grounding When Supplying Building Systems

    9-3. Grounding When Supplying Building Systems 9-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 38 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 9-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 39 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. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 40 9-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 41 9-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection 240 V 120 V 120 V 240 V 120 V...
  • Page 42 9-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
  • Page 43 54 – Fig. 10-2 24–Fig 10–3...
  • Page 44 Item Dia. Part Mkgs....182 367 ....185 352 ..
  • Page 45 Item Dia. Part Mkgs....174 824 ..PLG1 . . . 174 823 ..PLG3 .
  • Page 46 Item Dia. Part Mkgs....187 593 ..R3,VR1 046 819 ... . 187 190 .
  • Page 47 Item Part ....+186 238 ....013 367 ..
  • Page 51 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 52: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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