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OM-4407 203 236U
May 2004
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
(AC Available On AC/DC Models Only)
Trailblazer 301 G
Trailblazer DC
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . .
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TABLE OF CONTENTS SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8-1. Maintenance Label (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8-2. Routine Maintenance (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 8-3. Servicing Air Cleaner (Robin EH64-Powered Units) . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for nec
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the a hot engine. welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal Do not touch hot engine parts or just-welded parts objects can cau
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BATTERY ACID can BURN SKIN and EYES. STEAM AND HOT COOLANT can burn. Do not tip battery. If possible, check coolant level when engine is cold to avoid scalding. Replace damaged battery. Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water. ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, ENGINE HEAT can cause fire. foll
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READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as Perform engine and air compressor (if applicable) robots. maintenance and service according to this manual and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro- als. magnetically compatibl
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde ! des symboles adjacents aux directives. Soyez vigilant ! Il y a des risques de danger reliés Identifie un message de sécurité partic
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Le soudage, l’écaillement, le passage de la pièce Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adducti
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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif ( −) de batterie de la borne. RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles. Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et
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LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compres- Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur. moteur/compresseur (si applicable). Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence tr
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SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Engine Choke Battery (Engine) Clearance Read Operator’s Engine Amperes Volts Manual A V MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire Alternating Current Positive Negative Output (AC) Protective Earth Time Hours Seconds (Ground) s h Do not switch while Remote Constant Work Connection welding Receptacle Curr
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SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Rated Maximum Amperage Voltage Welding Generator Fuel Welding Open-Circuit Range In Range In Engine Mode Power Rating Capacity Output Voltage CC Mode CV Mode Robin EH64 Performer OHV 280 A, 25 V, 100% CC/DC 80 20 − 300 A Air-Cooled, Duty Cycle Two-Cylinder, Four- Continuous: 9.5 kVA// C Cycle ycle,, k kW W, 80/40 A, 80/40 A 20.5 HP 120/240 V AC, 60 10 gal Gasoline Engine 300 A, 25 V, 100% 10 − 33 V Hz, Single-Phase, CV/DC 50
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4-3. Fuel Consumption While Welding 8.51 2.25 7.57 2.00 6.62 1.75 5.68 1.50 ROBIN 1.25 4.73 KOHLER 3.79 1.00 2.84 0.75 1.89 0.50 IDLE − KOHLER AND ROBIN 0.95 0.25 0.00 0.00 050 100 150 200 250 300 DC WELD AMPERES AT 100% DUTY CYCLE 4-4. Fuel Consumption While Using Generator Power 8.51 2.25 7.57 2.00 6.62 1.75 5.68 1.50 ROBIN 4.73 1.25 KOHLER 3.79 1.00 2.84 0.75 1.89 0.50 IDLE − KOHLER AND ROBIN 0.25 0.95 0.00 0.00 0246 8 10 KW AT 100% DUTY CYCLE 206 136 OM-4407 Page 11 LITERS/HR. LITERS/HR. US
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4-5. Generator Power Curve The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 300 250 10,000 watts 216 200 150 100 50 0 0 10 2030 4050 607080 90 AC AMPERES Ref. 204 922 4-6. Duty Cycle Duty cycle is the percentage of 10 100% Duty Cycle at 280 Amperes DC minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. AC output is not available on all Continuous Welding models. 350 MIG/FCAW 300
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4-7. Stick And MIG Mode Volt-Ampere Curves The volt-ampere curves show the A. CC/AC Stick Mode minimum and maximum voltage and amperage output capabilities of 80 the welding generator. Curves of other settings fall between the 70 curves shown. AC output is not available on all 60 models. 50 40 30 20 10 0 0 50 100 150 200 250 300 350 AC AMPERES B. CC/DC Stick Mode 80 70 60 50 40 30 20 10 0 0 50 100 150 200 250 300 350 400 450 DC AMPERES C. CV/DC MIG Mode 45 40 35 30 25 20 15 10 5 0 0 100 200 3
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4-8. TIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/AC TIG Mode the welding generator. Curves of other settings fall between the 80 curves shown. AC output is not available on all 70 models. 60 50 40 30 20 10 0 0 50 100 150 200 250 300 350 AC AMPERES B. CC/DC TIG Mode 50 45 40 35 30 25 20 15 10 5 0 0 50 100 150 200 250 300 350 DC AMPERES 204 934 / 204 930 OM-4407 Page 14 DC VOLTS AC VOLTS
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SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Always securely fasten weld- Do not lift unit from end. ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. OR Do not mount unit by support- ing the base only at the four mounting holes. Use cross- supports to adequately sup- port unit and prevent dam
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5-2. Engine Prestart Checks (Robin EH64-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. This unit has a low oil pressure shutdown switch. However, some conditions may cause en- gine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Fuel Add fresh fuel before starting engine the first time (see main
