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OM-486 187 236H
February 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Engine Driven Welding Generator
Trailblazer 251 NT
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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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 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 necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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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 pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause par
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil On Battery (Engine) Clearance Read Operator’s Engine Amperes Volts A Manual 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 14 Work Connection Engine Choke welding 14 Receptacle Elec
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3-2. Dimensions, Weights, and Operating Angles Dimensions A B Height 33 in (838 mm) C C Width 18-3/4 in (476 mm) Do not exceed tilt angles or engine could Depth 45-1/2 in (1156 mm) be damaged or unit could tip. D Do not move or operate unit where it could A 18 in (457 mm) G tip. tip. 4 Holes B 16-1/2 in (419 mm) C 3/4 in (19 mm) E F D 3-1/8 in (79 mm) 25 25° E 32-3/4 in (832 mm) 25° ° 25° F 45-1/2 in (1156 mm) 25° ° G 13/32 in (10 mm) Dia. Weight 615 lb (279 kg) Engine End ST-800 426 3-3.
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3-4. Auxiliary Power Curve The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. 280 140 240 120 200 100 160 80 120 60 80 40 40 20 0 0 0 20 40 60 80 100 120 140 160 AC POWER AMPERES AT 120V 10 20 30 40 50 60 70 80 0 AC POWER AMPERES AT 240V ST-189 268 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated 100% Duty Cycle at 250 Amperes DC load without overheating. Exceeding duty cycle can damage unit and void warranty. C
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3-6. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/DC Mode the welding generator. Curves of other settings fall between the 80 curves shown. 70 60 50 MAX 40 30 MIN 20 10 0 0 50 100 150 200 250 300 350 DC AMPERES B. CV/DC Mode 50 40 30 MAX 20 MIN 10 0 0 100 200 300 400 500 600 DC AMPERES C. CC/AC Mode 80 70 60 50 40 MAX 30 MIN 20 10 0 0 50 100 150 200 250 300 350 AC AMPERES ST-189 266 / ST-189 267 / ST-189 265 OM-486 Page
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- Movement Airflow Clearance vided in base. 18 in Do not lift unit from end. Always ground generator (460 mm) frame to vehicle frame to pre- 18 in vent electric shock and static (460 mm) electricity hazards. 18 in (460 mm) 1 Generator Base OR 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 18 in 4 Grounding Cable 18 in
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4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well 4 1 Fill each cell with electrolyte to 3 bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electro- lyte level. If necessary, add electro- lyte to raise to proper level. Reins- tall vent caps. 6 Battery Charger Read and follow all instruc- 2
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4-4. Connecting The Battery Connect negative (–) cable last. – + Tools Needed: 3/8, 1/2 in Ref. ST-800 394-C / Ref. ST-189 925-A / Ref. S-0756-D 4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: 1/2 in ST-801 681 / Ref. ST-189 925-A 4-6. Connecting To Weld Output Terminals Do not connect to CC and CV terminals at the same time. 1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld O
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4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft Welding 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Amperes Amperes 10 – 60% 60 – 100% Duty 10 – 100% Duty Cycle Duty Cycle Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 *Weld cable si
