Miller Trailblazer 325 Diesel Owner's Manual
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Miller Trailblazer 325 Diesel Owner's Manual

Diesel engine driven welder
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Trailblazer 325 Diesel
OM-258900H
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welder/Generator
®
File: Engine Drive
2017−10

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  • Page 1 OM-258900H 2017−10 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Non-Critical TIG (GTAW) Welding Description Engine Driven Welder/Generator Trailblazer 325 Diesel ® File: Engine Drive For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING AUXILIARY EQUIPMENT ..........7-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 6 D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.

  • Page 7: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.

  • Page 10: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

  • Page 14: Dangers Liés À L'air Comprimé

    D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé...

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, D Remettre les portes, panneaux, recouvrements ou dispositifs...
  • Page 16 D Réduire le courant ou le facteur de marche avant de poursuivre le LA SORTIE DE RECHARGE et L’EXP- soudage. LOSION DE LA BATTERIE peuvent D Ne pas obstruer les passages d’air du poste. provoquer des blessures. LES CHARGES ÉLECTROSTATI- La recharge de batterie n’existe pas sur tous les QUES peuvent endommager les modèles.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.
  • Page 18 OM-258900 Page 14...

  • Page 19: Section 3 − Definitions

    Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbol Definition Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual. Safe89 2017−04 Moving parts can injure.
  • Page 20 Complete Parts List available at www.MillerWelds.com Engine Oil Engine Belt Drive Fuel Engine Stop Temperature Engine Coolant Battery (Engine) Glow Plug Temperature Check Valve Air Filter Idle (Slow) Clearance Engine−Driven Engine Run (Fast) 3−Phase Alternator with Rectifier Engine Output On Single Phase Alternator Engine Start...

  • Page 21: Section 4 − Specifications

    Complete Parts List available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output.

  • Page 22: Dimensions, Weights, And Operating Angles

    Complete Parts List available at www.MillerWelds.com 4-4. Dimensions, Weights, And Operating Angles Do not exceed tilt angles or engine could be damaged or unit could tip. Do not move or operate unit where it could tip. Weight: 638 lb (289 kg) Lifting Eye Weight Rating: 1250 lb (567 kg) Support Assembly Dimensions...

  • Page 23: Duty Cycle

    Complete Parts List available at www.MillerWelds.com 4-5. Duty Cycle 100% Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. This unit is rated at 325 amperes DC for continuous welding. NOTICE −...

  • Page 24: Fuel Consumption Curves

    Complete Parts List available at www.MillerWelds.com 4-7. Fuel Consumption Curves On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 24 hours of op- eration. Welding at 150 amps at 40% duty cycle uses approximately 1/2 gal- lon per hour, or about 22 hours of operation.

  • Page 25: Section 5 − Installation

    Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Do not move or operate unit where it could tip. Do not lift unit from end. Movement Do not weld on base. Welding on base can cause fuel tank fire or explosion.

  • Page 26: Grounding Generator To Truck Or Trailer Frame

    Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2012−03 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to Front Panel) wire from the generator equipment vehicle frame to prevent electric grounding terminal to bare metal on shock and static electricity hazards.

  • Page 27: Connecting The Battery

    Complete Parts List available at www.MillerWelds.com 5-4. Connecting the Battery − Tools Needed: 3/8, 1/2 in. 259 707 / Ref. S-0756-D ing the battery cables attach the positive Never disconnect the battery while Connect negative (−) cable last. the engine is running. (+) cable to the positive (+) battery termin- Battery is most easily accessed through al first, followed by negative (−) cable to...

  • Page 28: Overview And Engine Prestart Checks

    Complete Parts List available at www.MillerWelds.com 5-5. Overview And Engine Prestart Checks Generator Power Receptacles (see Exhaust Pipe 13 Coolant Overflow Bottle Section 7-1) Oil Fill Cap 14 Oil Filter Weld Output Terminals (see Section 5-6) Water Bypass Hose 15 Oil Dipstick Operator Controls (see Section 6) 10 Radiator Cap 16 Air Cleaner...
  • Page 29 Complete Parts List available at www.MillerWelds.com Engine shown with doors remo- ved. Doors must be in place when engine is running. Engine Left Side Engine must be cold and on a level sur- face. See maintenance label (Section 8-2) for fluid specifications. Starting engine for the first time: Add fresh fuel to bottom of filler neck.

  • Page 30: Weld Output Terminals

    Complete Parts List available at www.MillerWelds.com 5-6. Weld Output Terminals Stop engine. Turn off power before con- necting to weld output termi- nals. Do not use worn, damaged, undersized, or repaired cables. Positive (+) Weld Output Terminal Stick Negative (−) Weld Output Terminal Wire/TIG/Gouge Negative (−) Weld Output Terminal...

  • Page 31: Selecting Cable Sizes

    Complete Parts List available at www.MillerWelds.com 5-7. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 32: Remote Receptacle Information

    Complete Parts List available at www.MillerWelds.com 5-9. Remote Receptacle Information Socket* Socket Information 24 volts ac. Protected by supplementary protector C L N CB4. 24 VOLTS AC Contact closure to A completes 24 volt AC con- tactor control circuit and keeps engine at Run speed in all Wire modes.
  • Page 33 Complete Parts List available at www.MillerWelds.com Notes OM-258900 Page 29...

  • Page 34: Section 6 − Operating Welder/Generator

    Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 258 899-B / 250 071-A OM-258900 Page 30...

  • Page 35: Description Of Front Panel Controls (See Section 6-1)

    Complete Parts List available at www.MillerWelds.com 6-2. Description Of Front Panel Controls (See Section 6-1) Process/Contactor Switch age. With Process/Contactor switch in any next recommended oil change (see items 2 Wire position, use control to adjust voltage. and 3 earlier in this section). See Section 6-3 for Process/Contactor When a remote voltage/amperage control is switch information.

  • Page 36: Process/Contactor Switch, Engine Auto Speed, And Arc Control

    Stick/TIG. the «. transitions down one speed if power is ap- Miller recommends Hobart filler metals. For Stick applications, the Arc control var- propriate for load. OM-258900 Page 32...
  • Page 37 Output On / Wire / Flux Core Output On / Stick / Gouge Remote On/Off / Wire / Flux Core TIG processes also do not have arc control but process information is included in the table. Miller recommends Hobart filler metals. Process/Contactor Switch Arc Control SOFT...
  • Page 38 Complete Parts List available at www.MillerWelds.com Lift Arc start. Optimum for flat joint to end weld with crater fill, allow- Active ing for addition of filler, without loss of shielding gas Lift Arc start. Preset maximum current. Unit automatically pulses Active maximum output 40% of the time and 25% of peak output for 60% of the time based on 100 pulses per second.

  • Page 39: Stick Start Procedure − Scratch Start Technique

    If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. Miller recommends Hobart filler metals. 6-5. Lift-Arct TIG With Auto-Cratert And Auto-Stopt Arc Start With Lift-Arc TIG...

  • Page 40: Remote Voltage/Amperage Control

    Complete Parts List available at www.MillerWelds.com 6-6. Remote Voltage/Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-9). Process/Contactor Switch With remote control connected, weld output in Stick or TIG is deter- mined by a combination of front panel and remote control voltage/ amperage settings.

  • Page 41: Section 7 − Operating Auxiliary Equipment

    Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Supplementary Protectors Ref. 248 009 RC1 supplies 60 Hz single-phase power at Supplementary Protector CB3 Use GFCI protection when operat- weld/power speed. Maximum output is ing auxiliary equipment.

  • Page 42: Gfci Receptacle Information, Resetting, And Testing

    Complete Parts List available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Alternate location for red and green indicator LEDs. Orientation of receptacle may be different in other applications. RotGFCI1 2017-10 If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles Use GFCI protection when operat- button pops out, and the circuit opens to...

  • Page 43: Optional Excel Power

    Complete Parts List available at www.MillerWelds.com 7-3. Optional Excel Power Excel power option provides gener- ator power at idle speed and while welding. This allows most job site tools to operate properly at engine idle speed. Use GFCI protection when operating auxiliary equip- ment.

  • Page 44: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    Complete Parts List available at www.MillerWelds.com 7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each...

  • Page 45: Section 8 − Maintenance And Troubleshooting

    Complete Parts List available at www.MillerWelds.com SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions.

  • Page 46: Maintenance Label And Engine Maintenance Activities

    Complete Parts List available at www.MillerWelds.com 8-2. Maintenance Label And Engine Maintenance Activities Fuel Filter Add engine coolant as follows: Stop engine and let cool. Oil And Fuel Replace filter according to engine manual. Water Bypass Hose Oil Drain Valve Wipe up any spilled fuel.
  • Page 47 Complete Parts List available at www.MillerWelds.com 259 872 / 258 899-C OM-258900 Page 43...

  • Page 48: Replacing Air Cleaner

    Complete Parts List available at www.MillerWelds.com 8-3. Replacing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. Air Intake Tube Hose Clamp Air Cleaner...

  • Page 49: Adjusting Engine Speed

    Complete Parts List available at www.MillerWelds.com 8-4. Adjusting Engine Speed Engine speed is controlled by an electronic system that can only be adjusted by an engine Factory Authorized Service Station. Tampering with the electronic governor may void engine warranty. 8-5. Overload Protection Stop engine.

  • Page 50: Troubleshooting Tables

    Complete Parts List available at www.MillerWelds.com 8-6. Troubleshooting Tables A. Welding Trouble Remedy Low or no weld output; generator pow- Check control settings and all connections. er output okay at AC receptacles. Check fuse F5 and replace if necessary (see Section 8-5). Have Factory Authorized Service Agent check brushes, slip rings, and main rectifiers SR1, SR2, and SR3.
  • Page 51 Complete Parts List available at www.MillerWelds.com Trouble Remedy Engine does not crank. Supplementary protector CB8 may be open (see Section 8-5). Wait and retry. Check battery voltage. Check battery connections; clean and tighten if necessary. Check Engine Control switch and engine wiring harness connections. Have Factory Authorized Service Agent check circuit breaker CB8.

  • Page 52: Section 9 − Parts List

    Complete Parts List available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity Recommended Spare Parts ....259935 Filter Kit, Kubota (Includes air cleaner element, fuel, oil filters) .
  • Page 53 Complete Parts List available at www.MillerWelds.com Notes OM-258900 Page 49...

  • Page 54: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-258900 Page 50...
  • Page 55 258849-E OM-258900 Page 51...

  • Page 56: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 57 11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 58 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 59 11-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...
  • Page 60 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 61 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording Owner’s Manual and national, state, and local codes. Customer-supplied equipment is required if generator will sup- ply standby power during Fused...
  • Page 62 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current Load (Watts)
  • Page 63 Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 64 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2017 Miller Electric Mfg. Co. 2017−01...

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