Miller Electric HJ134589 user manual

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1978
April FORM: OM-457C
Effective With Serial No. HJ134589
MODEL
Trailblazer 22G
OWN
ERS
ITIIIIER
MANUAL
MILLER
ELECTRIC MFG.
CO.
718 S. BOUNDS ST. P.O.
Box 1079
WI
APPLETON, 54912 USA
NWSA
CODE NO. 4579
PRINTED
IN U.S.A.

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LIMITED WARRANTY EFFECTIVE: FEBRUARY 1978 20, a This all supersedes MILLER warranties and is ex warranty previous clusive with no other or warranties or guarantees expressed implied. LIMITED WARRANTYMiller Electric 1. Arc 1 Mfg. Co.. Apple- welders, sources, and components. . year power Wisconsin that ton, warrants to Customer all new and unused 3 2. main rectifiers years Original power furnished is Equipment by Miller free from defect in (Labor 1 only) year the workmanship and material as o

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ERRATA SHEET in This sheet lists ex.cenXioi~s.tadata aooearina later in After this manual was refinements occurred. printed, equipment design this manual. AMENDMENTTO SECTION 3 INSTALLATION Amend Section 3-3. TERMINAL EQUIPMENT GROUNDING this do not However, machine has Normally engine-driven welding generators require grounding. auxiliary power the of frame and case is recommended. Also, unusual circumstances re plant capability; therefore, grounding may machine For these reasons a convenient t

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- Add CAUTION block of Section at beginning / terminals when the is Disconnect CAUTION.: The weld are the~ output electrically energized engine running. cables when not and do not touch the terminals when the is we/ding we/ding engine running. output AMENDMENT TO SECTION 9- ENGINE MAINTENANCE Amend Section SERVICE 9-3. GOVERNOR Weld of this is 1850 speed engine rpm. Amend Section 9-4. CARBURETOR FLOAT SETTING Carburetor Effective With Serial No. HJ185451 Change I~1t~ Do the The float when viewe

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1. Loosen the nuts & 8) and the hardware (10) the socket (9) to the linkage (6 remove securing linkage governor. Rotate socket until the throttle is about 1/32 inch from the (1). A clockwise thelinkage (9) plate (2) stop stop rotation of the socket will shorten the and reduce the counterclockwise (9) linkage (7) a linkage governor gap; rotation of the socket will and widen the (In cases it (9) the (7) some linkage lengthen governor linkage gap. may be the socket nuts to the itself to obtain the

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8. the two to maintain the desired Tighten locking nuts (13) the governor sensitivity. Readjust governor sensitivity 7. Step by repeating MUSTbe ) 1~ Whenever the 7) is the 6) readjusted. sensitivity (Step adjusted, governor speed (Step governor Whenever the is the 71MAY need speed (Step 61 adjusted, sensitivfty (Step readjustment. governor governor Amend Section 9-10. HIGH ALTITUDE CARBURETOR MODIFICATION 9-7) (Optional) (Figure The Walbro carburetor be with Teledyne can an main for (above 400

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No. Listed With )tem Dia. Part Replaced In Parts List Part No. - No. Description Mkgs. Quantity 010318 015 602 - - 6 VALVE, shut off w/strainer fuel 1 053724 966 33 053 fan 2 GUARD, 017421 53 049685 door 2 CATCH, 77 Zi 036259 036 377 REACTOR 1 80 VS1 025932 024 017 0.75 uf 65 volts ac (Eff with S/N SUPPRESSOR, HK311202) 1 4 TAC 032 936 Deleted Page 5 HM 032 936 032 936 METER 1 (dia. Page mkg. changed) 97 039 269 080 487 FUSE BOX with 1 (Eff S/N HJ211479) 601158 - in with HJ21 2 BLANK, 7/8 (Eff S

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7676 TABLE OF CONTENTS Section No. No. Page SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1 -1. Introduction 1 - 1 2. General Precautions - 1 3. Arc 3 Welding - 4 1 4. Standards Booklet Index SECTION 2 INTRODUCTION 5 2-1. General - 5 2 2. Receiving-Handling - 5 2 3. Description 5 2-4. Safety SECTION 3 INSTALLATION 3-1. Location 3-2. Weld Connections Output - 3 3. Terminal Equipment Grounding 3-4. Remote Control Connections Amperage 7 3- 5. 120/240 Volts AC Terminals.. SECT

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Section No. No. Page 8 SECTION GENERATOR MAINTENANCE 8-1. General 14 8 - 2. Collector Brushes 14 Ring 8- 3. Cables 14 Welding SECTION 9 ENGINE MAINTENANCE 9-1. Lubrication 14 9~ 2. 14 Coolant System 9-3. Governor Service 15 15 9. 4. Carburetor Float Setting 9- 5. Vacuum Circuit Air Filter 15 9. 6. Idle Control Time 15 Delay Adjustment 9- 7. Carburetor Air Selector 15 Temperature 9- 8. Air Cleaner Service 16 9- 9. Idle Control/Governor 17 Linkage Adjustment 9.10. Altitude Carburetor Modificati

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SECTION 1-SAFETY RULES FOR OPERATION OF ARC POWER WELDING SOURCE 1-1. harmful concentrations of INTRODUCTION toxic fumes. Adequate local exhaust be ventilation must used, or each in the area person We as well the learn by experience. as operator must wear an Learning safety through personal air-supplied respirator. For experience, like a child a hot stove is beryllium, both must be used. touching harmful, unwise. wasteful, and Let the experience of others teach you. Metals coated with or mater

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This includes: caustic a thorough steam or (or a cleaning Protect valves from cylinders particularly bumps, falls, falling solvent or water washing, depending on the combustibles and weather. when objects, Replace caps securely moving solubility) followed by and with or purging inerting nitrogen cylinders. carbon dioxide, and protective as recom using equipment mended in A6.0. below level Waterfilling just working may Stuck valve. Do NOT a hammer wrench to a use or open substitute for inerting.

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Use charts (available for safe with or pressure from your supplier) operation low-reflective, non.cornbustible screens and free floor efficient, recommended settings on regulators. panels. Allow for air circulation, particularly as pressure level. Check for leaks on first and there pressurization regularly after. Brush with solution of soap (capful Ivory Liquid or who the weld. Provide face shields for all Viewing persons of water). Bubbles indicate leak. Clean equivalent per gallon will be at t

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2. Electrode Holders Do while not circuit or polarity welding. open power change in If, an it must be disconnected, guard against emergency, insulated shock Fully electrode holders should be burns, or flash from switch used. Do NOT arcing. use holders with screws. protruding Leaving unattended. shut OFF and dis equipment Always 3. Connectors connect all to power equipment. Fully insulated Power disconnect switch must be available near the lock-type connectors should be used to welding join cable

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SECTION 2- INTRODUCTION Rated Welding Current Ranges Open-Circuit Weight Welding Dimensions (Pounds) Current In Amperes Voltage Amperes ?~i~E Coarse Fine Range Range Power (Inches) Output Range Ranges 3kva 120 Volts AC 45- 85 50/60 Hz. 350 From Mm. - 43-1/2 65-140 Height While 40V To To Max. Of 55 To 90 Welding @ 45 1560 100-220 Width -25 1520 Each Coarse DC Volts 7.5 kva 100% 475 Amps - 130 . 300 Depth 63 120/240 Volts AC Duty Cycle Range 220 -475 50/60 Hz. As Power Plant ~. 2-1. Figure Specifi

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IMPORTANT NOTE I I U Under this installation, and main will be heading, operating, Under this statements heading, explanatory tenance or will be found that if the procedures practices found that need to obtain most special emphasis not followed result in to carefully nay damage equip- of the efficientoperation equipmrrnt. merit. I U INSTALLATION SECTION 3 - On is for 3 - 1. LOCATION most welding a lifting device provided (Figure 3-1) generators if fork lift vehicle is used for moving the unit.

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3- 3. EQUIPMENT GROUNDING TERMINAL 3-2) (Figure Normally, do not engine-driven Welding generators require However, since this unit has grounding. auxiliary power plant capability, of the frame and case be grounding may required, A grounding terminal has been provided on the front panel for this (see 3-2). For detailed purpose Figure grounding instructions consult local or state codes or the latest your of issue the National Electrical Code. 3-4. REMOTE AMPERAGE CONTROL CONNECTIONS (Figure 5-1) T

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m 260 U, 250 I I 7.7SKVA The FINE AMPERAGE control be rotated must to the 100 (full whenever the 240 counterclockwise) position I.SKVA 120/240 volts is utilized. power plant being I I KVA 230 14.3 ~ 220 16.1 KVA The will in accordance with the load voltage vary applied to ~ the 120/240 volts terminals. The voltage at various loads may 210 be determined from 3-4. Figure 200 70 80 90 110 120 0 10 20 30 40 50 60 100 ~ POWER .MPERES 8-005 185 Volts AC Terminals 3-4. AC Power Curve For 120/240 Figure

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4-4. AIR CLEANER NOTE is element The air cleaner this is equipped with, a dry engine The air cleaner re with a filter element. type replaceable If the does not additional no initial service. battery require any charg quires the to the into ing, only step required place battery is to the () cable 4-5. FUEL operation connect negative battery to the () terminal the negative on battery. . 4-2 illustrates fuel consumption under specific typical Figure conditions. Fuel will from one load consumption

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SECTION 5-FUNCTION OF GENERATOR CONTROLS The contacts of the FINE AMPERAGE control are of the continuous contact it type, thereby making to fine the while possible adjust amperage output welding i The scale the FINE is surrounding AMPERAGE control calibrated from 0 100 in to percent increments of ten. Due to this should if the percentage calibration, it be noted that is this scale select operator using to a fine setting, amperage the is in operator selecting a percentage of the coarse range us