Miller Trailblazer 330 Diesel Owner's Manual
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Miller Trailblazer 330 Diesel Owner's Manual

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OM-291102B
2023-12
Processes
Multiprocess Welding
Description
Engine Driven Welder/Generator
Trailblazer
330 Diesel
®
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-291102B 2023-12 Processes Multiprocess Welding Description Engine Driven Welder/Generator Trailblazer 330 Diesel ® OWNER’S MANUAL 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS 5-11 Selecting Cable Sizes* ....................32 SECTION 6 –...

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

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

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

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

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

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...

  • Page 18: Informations Relatives Aux Cem

    2-8. Informations relatives aux CEM 3. Ne pas courber et ne pas entourer les câbles autour de votre Le courant électrique qui traverse tout conducteur génère des corps. champs électromagnétiques (CEM) à certains endroits. Le courant is- su d’un soudage à l’arc (et de procédés connexes, y compris le sou- 4.

  • Page 19: Section 3 - Definitions

    Safe � Complete Parts List is available at www.MillerWelds.com SECTION 3 – DEFINITIONS Falling unit can cause injury and damage. Do not move unit where two wheels are at a different height and un could tip avoid tipping. Be careful when moving unit over uneven surfaces. Safe 3-1.
  • Page 20 Single Phase Engine Start Alternator Output Engine RPM � Complete Parts List is available at www.MillerWelds.com Circuit Breaker Arc Control Supplementary Engine Oil Engine Choke Air Filter Protector Direct Current Percent (DC) Spool Gun Fuel Idle (Slow) Rated No−Load Push Button Fuel Voltage (OCV) Air Carbon Arc...

  • Page 21: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 22: Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.MillerWelds.com 4-7. Dimensions, Weights, And Operating Angles Dimensions External Dimensions Height (With Exhaust) 32.41 in. (823 mm) Do not exceed tilt angles or engine could Width 20.6 in. (523 mm) be damaged or unit could tip. Depth 45.72 in.

  • Page 23: Dimensions For Units With Optional Running Gear

    � Complete Parts List is available at www.MillerWelds.com 4-8. Dimensions For Units With Optional Running Gear A. Running Gear Dimensions Height To Top Of Exhaust Pipe: 42.61 in. (108.23 cm) Height To Top Of Handle: 40.18 in. (102.06 cm) Width: 31.45 in.

  • Page 24: Fuel Consumption Curves

    � Complete Parts List is available at www.MillerWelds.com 4-10. Fuel Consumption Curves WeldIng Weld Power Run No-Load Idle AMPERES Auxiliary Power Aux Power Run No-Load Carb Aux Power Excel Idle KILOWATTS OM-291102 Page 20...

  • Page 25: Stick Mode Volt-Ampere Curves

    � Complete Parts List is available at www.MillerWelds.com 4-11. Stick Mode Volt-Ampere Curves The volt-ampere curves show the minimum XX10 Electrode and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. 150 Amps Mid 20 Amps Mid 150 Amps Min...

  • Page 26: Mig Mode Volt-Ampere Curves

    � Complete Parts List is available at www.MillerWelds.com 4-12. MIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. 35 Volts 25 Volts 14 Volts AMPS...

  • Page 27: Generator Power Curve

    � Complete Parts List is available at www.MillerWelds.com 4-14. Generator Power Curve The AC generator power curve shows the 120 Volt Excel generator power available in amperes at the receptacles. Tools and motors are designed to operate within 10% of 120/240 VAC. AMPS 240 Volt AMPS...

  • Page 28: Battery Charge Curve (Models With Battery Charge Option)

    � Complete Parts List is available at www.MillerWelds.com 4-15. Battery Charge Curve (Models With Battery Charge Option) 24 Volt 12 Volt AMPS 4-16. Wireless Remote (Optional) Regulatory Approval This device complies with Part 15 of the FCC rules. Operation is subject to the following conditions: 1.

  • Page 29: Section 5 - Installation

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

  • Page 30: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle shock and static electricity hazards.

  • Page 31: Installing Exhaust Pipe

    � Complete Parts List is available at www.MillerWelds.com 5-4. Installing Exhaust Pipe Stop engine and let cool. Engine backfire can cause severe burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust AUTO-SPEED outlet. START Do not point exhaust pipe toward LP fuel tank (if equipped).

  • Page 32: Engine Prestart Checks

    � Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W-30 synthetic blend engine oil. � Follow run-in procedure in engine manual.

  • Page 33: Connecting Or Replacing The Battery

    � Complete Parts List is available at www.MillerWelds.com 5-6. Connecting Or Replacing the Battery Connect negative (-) battery cable last. Battery is most easily accessed by opening left rear side panel. � Do not allow the battery cables to touch opposing terminals.

  • Page 34: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-7. Weld Output Terminals Stop engine. Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Positive Weld Output Terminal Electrode Output Terminal (Polarity Reversing...

  • Page 35: Remote Receptacle Information

    � Complete Parts List is available at www.MillerWelds.com 5-9. Remote Receptacle Information Socket* Socket Information Remote 14 24 volts AC. Protected by supplementary pro- tector CB4. C L N Contact closure to A completes 24 volt AC 24 Volts AC contactor control circuit and keeps engine at Output (Contactor) Run speed in all modes.

  • Page 36: Selecting Cable Sizes

    � Complete Parts List is available at www.MillerWelds.com 5-11. 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 37: Section 6 - Operation

    SECTION 6 – OPERATION 6-1. Front Panel Controls CHARGE AUTO-SPEED Auto-Set ™ START 2 Adjust Control/Select Knob 5 USB 1 Engine Control Switch Push to select and rotate to navigate menus Use for software upgrade and collecting er- Use switch to start engine, select speed, and adjust values.

  • Page 38: Main Screen

    6-2. Main Screen 1 Fuel Level 5 Arc Control 10 Glow Plug Displays current fuel level. Displays arc control setting. Indicates if glow plug is on. 2 Weld Process 6 Process Selection Button 11 ArcReach (AR) Displays current weld process. Opens process selection screen.

  • Page 39: Menu Screen

    6-3. Menu Screen 1 System Settings 3 System Info 4 Productivity Select to change unit operation parameters. Select to check and update software, check Select to check unit usage hours. See Section 6-4. and download summary file, and restore unit to factory defaults (see Section 6-19).

  • Page 40: System Settings Screen

    6-4. System Settings Screen To change System Settings: � Rotate Adjust Control/Select button to select a setting. � Press Adjust Control/Select button on desired setting. � Rotate Adjust Control/Select button to update the setting. � Press Adjust Control/Select button to save the setting, or press the Back but- ton to discard setting change.

  • Page 41: Cable Length Compensation (For Cv Process)

    6-6. Cable Length Compensation (For CV Process) � Refer to Section 6-4 for enabling Cable Length Calibration (CLC) � Use of Auto-Set requires WLC or CLC to be enabled. CLC is a another method for overcoming voltage drop when using long cable runs and the CV process. CLC uses a test weld to measure the exact voltage drop from your weld cables.

  • Page 42: Process Screen

    6-8. Process Screen 1 Process Button 2 Menu Button To change weld process, rotate Adjust Con- trol/Select button to desired process and press button to select. Press to open process selection screen. Press to open Menu. Process Typical Process Application Polarity* SMAW XX18 (STICK) Constant current process.

  • Page 43: Weld Settings

    6-9. Weld Settings To access the weld settings, press Settings button. To change a particular parameter (parame- ters change based on current process): � Rotate the Adjust Control/Select knob to specific parameter. � Press the Adjust Control/Select knob to select. �...

  • Page 44: Auto-Set Functionality

    6-10. Auto-Set Functionality ™ 1 Auto-Set Button Press to turn Auto-Set On or Off. 2 Auto-Set Option 1 3 Auto-Set Option 2 4 Auto-Set Option 3 Rotating knob clockwise moves cursor left, rotating counterclockwise moves cursor right. Press knob or NEXT button to select option CHARGE and move to next selection.

  • Page 45: Stick Start Procedure-Scratch Start Technique

    For optimal starting performance, a good clean contact must be made between the electrode and workpiece. � Miller recommends Hobart filler metals. 6-12. Lift-Arc™ TIG With Auto-Stop™ And Auto-Crater™ Arc Start With Lift-Arc TIG Arc Start With Lift-Arc Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted.

  • Page 46: Typical Stick Welding Connections And Control Settings

    XX18 Process: 6013, 7018, 7024, all stain- less steel electrodes, and any other low hy- drogen electrodes not mentioned. nutdriver chippinghammer � Miller recommends Hobart filler metals. workclamp wirecutter frontcutter greasegun filterwrench OM-291102 Page 42 file paintbrush...

  • Page 47: Typical Mig Welding Connections And Settings

    6-14. Typical MIG Welding Connections and Settings A. Solid Wire Applications Stop engine. � This section provides general guide- lines and may not suit all applications. 1 Work Clamp 2 Wire Feeder 3 MIG Gun 4 Gun Trigger Plug 5 Voltage Sensing Clamp 6 Gas Cylinder: 75/25 Argon-Based Gas for Short Circuit Transfer;...
  • Page 48 � Do a test weld. To increase arc length, 3/4 in. increase voltage. To decrease arc length reduce voltage or increase wire philips head wrench crescent wrench feed speed. � Miller recommends Hobart filler metals. nutdriver chippinghammer OM-291102 Page 44...

  • Page 49: Typical Spool Gun Welding Connections And Control Settings

    6-15. Typical Spool Gun Welding Connections And Control Settings 3/4 in. Connect Weld power cable from spool gun � � ps head wrench crescent wrench Miller recommends Hobart filler This section provides general guide- to the positive terminal. metals. lines and may not suit all applications.

  • Page 50: Remote Voltage/Amperage Control

    6-16. Remote Voltage/Amperage Control 1 Remote Receptacle RC41 Connect optional remote voltage/amperage (V/A) control to Remote Control (RC) recep- tacle (see Section 5-9). Adjust Control/Select Button � Remote weld setting must be set to AU- TO. If set to OFF, remote connection will be ignored.

  • Page 51: Engine Cold Weather Starting And Operation

    1 For temperatures below 0°F (-18°C), synthetic oil improves engine starting. 2 For additional engine oil specification see Engine Maintenance Label or Engine Operators Manual. 3 Times listed are for the standard Miller Part No. 242954, Engine Block Heater, 120V. — Not required.

  • Page 52: Updating Software

    6-19. Updating Software Preparing For Software Update Step 1. Verify current software version installed. Step 2. Press Settings button and use Adjust Control/Select button to select System Info. The current software revision is displayed. Step 3. Verify that USB thumb drive is good by inserting it into USB receptacle on bottom of remote panel. Press ”Download Service File" from menu.

  • Page 53: Section 7 - Battery Charging

    SECTION 7 – BATTERY CHARGING 7-1. Battery Charging Guidelines Keep battery charging cables away Disconnect cables from weld termi- Stop welder/generator engine. from vehicle hood, door, and mov- nals before charging a battery. Weld Before charging battery, read the ing parts. terminals are electrically live during Safety Precautions at the beginning battery charging.

  • Page 54: Connecting Installed Battery To Optional Battery Charge Receptacle

    7-3. Connecting Installed Battery To Optional Battery Charge Receptacle Negative Post Grounded Stop welder/generator engine. � Battery will not charge if it is com- pletely dead. This happens at 1 volt. If battery Negative (−) post is grounded to Before charging battery, check po- chassis, connect red (Positive) battery larity of battery posts.

  • Page 55: Setting Battery Charge Controls

    7-4. Setting Battery Charge Controls To start charging a battery: � Select either 12 V or 24 V with the con- trol/select button depending on the type of battery being charged. � Connect the battery terminals as de- scribed in Section 7-2 and 7-3. �...

  • Page 56: Section 8 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – OPERATING AUXILIARY EQUIPMENT 8-1. Generator Power Receptacles Maximum output from duplex receptacles is 6 Supplementary Protector CB3 Use GFCI protection when operating 2.4 kVA/kW. auxiliary equipment. If unit does not have GFCI receptacles, use GFCI- CB3 protects duplex receptacles from over- 120/240 V receptacle supplies 60 Hz single-...

  • Page 57: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 8-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 58: Optional Excel Power

    � Complete Parts List is available at www.MillerWelds.com 8-3. Optional Excel Power Excel power option provides generator power at idle speed and while welding. This allows most job site tools to operate properly at engine idle speed. Use GFCI protection when operat- ing auxiliary equipment.

  • Page 59: Wiring Instructions For 240 Volt, Single-Phase Plug (Nema 14-50P)

    � Complete Parts List is available at www.MillerWelds.com 8-5. Wiring Instructions For 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. 1 Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex re- ceptacle shares a load with one half of 240 V 120V...

  • Page 60: Wiring Instructions For 240 Volt, Single-Phase Plug (Nema 6-50P)

    � Complete Parts List is available at www.MillerWelds.com 8-6. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P) The plug can be wired for a 240 V, 2-wire load. 1 Plug Wired for 240 V, 2-Wire Load 2 Load 1 (Brass)Terminal 3 Load 2 (Brass) Terminal 4 Ground (Green) Terminal Current Available in Amperes...

  • Page 61: Section 9 - Can-Bus Connection

    SECTION 9 – CAN-BUS CONNECTION 9-1. CAN-Bus Connection 1 CAN-Bus Connector A CAN-bus connection is provided to allow read-only data communication. The data is available through the CAN-bus connector lo- cated inside left-hand access door, on the main harness. Data is transmitted when the unit is On.

  • Page 62: Trailblazer J1939 Messages

    9-2. Trailblazer J1939 Messages Message Notes Acro- ID (Hex) Start Length (Deci- Posi- (Deci- Rate mal) tion mal) (ms) Engine Speed 0 to 8031.875rpm 0.125rpm/bit 0 EEC1 0CF004D1 61444 2 bytes offset Battery Potential 0 to 3212.75V, 0.05V/bit, 0 offset 18FEF7D1 65271 2 bytes...
  • Page 63 Table 9–2. Error State Error Value Detection NO ERROR WELD BOOST CONNECTOR FAULT Connector RC2 not plugged in. WELD BOOST VBUS HIGH FAULT Weld module bus voltage exceeded threshold during operation. WELD BOOST VBUS LOW FAULT Weld module bus voltage below threshold while engine running. WELD BOOST FAULT Low weld module bus voltage after soft start.
  • Page 64 J1939-73 SPN Name Detection DTC Set Parameter Time to action or Recov- SAE J1939 number of error Action ery From Table C1 detection Error Starter error 5.00- proprietary Starter running time Starter running time 12.0 sec or more Engine E+05 exceed threshold time is above 12sec Stop...

  • Page 65: Section 10 - Generator/Engine Maintenance

    SECTION 10 – GENERATOR/ENGINE MAINTENANCE 10-1. Maintenance Screen The Maintenance screen displays hours re- maining for service items and allows the user to reset service hours and change the inter- val (only shorter than recommended.) Press the Home Button to go to the Home screen.

  • Page 66: Routine Generator/Engine Maintenance

    10-2. Routine Generator/Engine Maintenance � Use information displayed on the LCD display to assist in scheduling maintenance (see Section 10-1). � Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by a Factory Authorized Service Agent.

  • Page 67: Maintenance Label

    10-3. Maintenance Label OM-291102 Page 63...

  • Page 68: Replacing Air Cleaner

    10-4. Replacing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty. 1 Air Intake Tube AUTO-SPEED 2 Hose Clamp START 3 Air Cleaner Loosen hose clamp, slide air cleaner to-...

  • Page 69: Engine Maintenance Activities

    10-5. Engine Maintenance Activities Stop engine and let cool. Replace fuel filters according to engine Drain engine coolant according to procedure manual. in engine manual. Oil And Fuel Replace fuel lines if cracked or worn. Add engine coolant as follows: 1 Oil Drain Valve 2 Oil Filter Wipe up any spilled fuel.

  • Page 70: Overload Protection

    10-6. Overload Protection 1,2,5,12 9,10 Stop engine. Disconnect negative (-) 4 Fuse F4 9 Circuit Breaker CB3 (Under Cover) battery cable. Protects battery charge board from over- Protects non Excel 120V receptacle. � load. If open, battery will not charge. If a fuse opens, it usually indicates a more serious problem exists.

  • Page 71: Servicing Optional Spark Arrestor

    10-7. Servicing Optional Spark Arrestor Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark ar- restor if screen wires are broken or missing. AUTO-SPEED START tools/ flathead philips head wrench crescent wrench 1/4 in. ps head wrench crescent wrench...

  • Page 72: Section 11 - Troubleshooting

    Always check unit before applying power. See Pre-Power Checks. SECTION 11 – TROUBLESHOOTING 11-1. Front Panel Display Code Information LCD Message Help Code Problem Possible Cause Potential Solution Engine Oil Pressure Error - ERR PF00 Despite RPM, oil pressure Indicates malfunction of oil Contact a Factory Authorized Have Unit Serviced switch is ON.
  • Page 73 Always check unit before applying power. See Pre-Power Checks. LCD Message Help Code Problem Possible Cause Potential Solution Inverter Current Sensor Error ERR DE00 Output Current Sensor not Indicates malfunction of out- Contact a Factory Authorized - Have Power Module reading correctly.
  • Page 74 Always check unit before applying power. See Pre-Power Checks. LCD Message Help Code Problem Possible Cause Potential Solution Batt Final Check Battery Er- ERR BE03 Too many retries on battery Bad battery. Replace battery. ror - Bad Battery Replace charge final test. Battery Batt Charge Timer Expired ERR BX00...

  • Page 75: Welding Troubleshooting

    Always check unit before applying power. See Pre-Power Checks. 11-2. Welding Troubleshooting Trouble Remedy No weld output. Check weld control settings. Check weld connections. Verify generator output is not present. Disconnect equipment from generator power receptacles during start-up. Increase front panel and/or remote voltage/amperage control settings (see Sections 6-9 and 6-16). Check and secure connections to Remote receptacle RC41 (see Sections 5-9).

  • Page 76: Generator Power Troubleshooting

    Always check unit before applying power. See Pre-Power Checks. 11-3. Generator Power Troubleshooting Trouble Remedy No power output. Reset supplementary protectors (see Section 8-1). Have Factory Authorized Service Agent check brushes, slip rings, and circuit board PC2. Low power output. Check and clean air cleaner as necessary.

  • Page 77: Engine Troubleshooting

    Always check unit before applying power. See Pre-Power Checks. 11-4. Engine Troubleshooting Trouble Remedy Engine does not crank. Supplementary protector F1 or F2 may be open. Wait and retry. Check battery voltage. Check battery connections; clean and tighten if necessary. Check Engine Control switch and engine wiring harness connections.

  • Page 78: Battery Charge/Jump Troubleshooting

    Always check unit before applying power. See Pre-Power Checks. 11-5. Battery Charge/Jump Troubleshooting Trouble Remedy No battery charge/jump output. Be sure battery is connected. Check battery voltage, charging may be finished. Have Factory Authorized Service Agent check battery charge circuitry. �...

  • Page 79: Section 12 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 12 – PARTS LIST 12-1. Recommended Spare Parts Recommended Spare Parts Part No. Description Item No. Dia. Mkgs. Quantity 292189 Brushholder Assy, Generator 280236 Receptacle, Gfci 15/20a 281761 Fuse, Mini Blade Atm 30. Amp 32 Volt 281760 Fuse, Mini Blade Atm 20.

  • Page 80: Section 13 - Electrical Diagrams

    SECTION 13 – ELECTRICAL DIAGRAMS Figure 13-1. Circuit Diagram Page 1 of 2 OM-291102 Page 76...
  • Page 81 292067-A-1 OM-291102 Page 77...
  • Page 82 Figure 13-2. Circuit Diagram Page 2 of 2 OM-291102 Page 78...
  • Page 83 292067-A-2 OM-291102 Page 79...

  • Page 84: Section 14 - Generator Power Guidelines

    SECTION 14 – 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. 14-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 85 14-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing system.
  • Page 86 14-5. 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 87 Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 14-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
  • Page 88 14-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 89 14-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 90 14-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension 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 (Amperes)
  • Page 91 Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. LIMITED WARRANTY - Subject to the terms and...
  • Page 92 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-12...

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