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Miller Trailblazer 251 - User Manual

Miller Trailblazer 251
48 pages
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Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW)
Engine Driven Welding Generator
OM-485 181 594F
November 1997
Trailblazer 251
Visit our website at
www.MillerWelds.com

Table of Contents

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Summary

Section 1 - Safety Precautions - Read Before Using

1-1. Symbol Usage

Explains the meaning of symbols used in the manual for safety warnings.

1-2. Arc Welding Hazards

Details hazards associated with arc welding processes and protective measures.

1-3. Engine Hazards

Outlines potential dangers related to the engine, fuel, and exhaust systems.

1-4. Additional Symbols For Installation, Operation, And Maintenance

Covers symbols for specific operational and maintenance hazards and precautions.

1-5. Principal Safety Standards

Lists key safety standards and codes relevant to welding equipment.

1-6. EMF Information

Discusses electromagnetic field effects and how to minimize exposure.

Section 2 - Definitions

2-1. Symbol Definitions

Provides a glossary of symbols used in the manual for clarity and understanding.

Section 3 - Specifications

3-1. Weld, Power, And Engine Specifications

Details technical specifications for welding output, auxiliary power, and engine.

3-2. Dimensions, Weights, And Operating Angles

Lists physical dimensions, weight, and safe operating angles for the unit.

3-3. Fuel Consumption

Provides data on the unit's fuel consumption rates under various operating conditions.

3-4. Auxiliary Power Curve

Illustrates the available auxiliary power output at different amperage levels.

3-5. Duty Cycle

Explains duty cycle percentages and their impact on unit performance and warranty.

3-6. Volt-Ampere Curves

Graphic representation of voltage and amperage output capabilities across different modes.

Section 4 - Installation

4-1. Installing Welding Generator

Step-by-step guide for physically installing the welding generator unit.

4-2. Engine Prestart Checks

Essential checks to perform on the engine before starting the unit.

4-3. Connecting The Battery

Instructions for properly connecting the unit's battery for operation.

4-4. Connecting To Weld Output Terminals

Guidance on connecting cables to the correct output terminals for welding.

4-5. Selecting Weld Cable Sizes

Table for choosing appropriate weld cable sizes based on amperage and length.

4-6. Remote 14 Receptacle Information

Details the function and pin configuration of the Remote 14 receptacle.

4-7. Adjusting MIG Weld Puddle Consistency

Procedures for fine-tuning MIG welding puddle characteristics for optimal welds.

Section 5 - Operating Welding Generator

5-1. Front Panel Controls

Explanation of the function of each control on the generator's front panel.

5-2. Remote Amperage;Voltage Control

How to connect and use optional remote controls for amperage and voltage adjustment.

Section 6 - Operating Auxiliary Equipment

6-1. Auxiliary Power Receptacles And Circuit Breakers

Information on using auxiliary power outlets and understanding circuit breakers.

Section 7 - Maintenance And Troubleshooting

7-1. Routine Maintenance

Schedule and procedures for regular maintenance tasks to ensure optimal performance.

7-2. Maintenance Label

Details found on the engine's maintenance label for quick reference.

7-3. Servicing Air Cleaner

Step-by-step guide for cleaning and maintaining the air cleaner element.

7-4. Servicing Optional Spark Arrestor

Instructions for inspecting and cleaning the optional spark arrestor.

7-5. Changing Engine Oil, Oil Filter, And Fuel Filter

Procedures for replacing engine oil, oil filter, and fuel filter.

7-6. Adjusting Engine Speed

How to adjust engine idle and weld/power speeds for proper operation.

7-7. Overload Protection

Explanation of overload protection features and circuit breaker reset procedures.

7-8. Troubleshooting

Guidance for diagnosing and resolving common welding and engine operational issues.

Section 8 - Electrical Diagram

Section 9 - Auxiliary Power Guidelines

9-1. Selecting Equipment

Advice on choosing auxiliary equipment compatible with the generator's output.

9-2. Grounding Generator To Truck Or Trailer Frame

Instructions for properly grounding the generator when mounted on a vehicle frame.

9-3. Grounding When Supplying Building Systems

Guidance on grounding the generator when connecting to building electrical systems.

9-4. How Much Power Does Equipment Require?

Explains how to calculate power requirements for connected equipment.

9-5. Approximate Power Requirements For Industrial Motors

Table listing typical power requirements for various industrial motors.

9-6. Approximate Power Requirements For Farm;Home Equipment

Table listing typical power requirements for farm and home equipment.

9-7. Approximate Power Requirements For Contractor Equipment

Table listing typical power requirements for contractor equipment.

9-8. Power Required To Start Motor

Explains how to determine the starting amperage needed for motors.

9-9. How Much Power Can Generator Supply?

Guidance on generator output limits and starting motor loads.

9-10. Typical Connections To Supply Standby Power

Diagrams and instructions for connecting the generator for standby power.

9-11. Selecting Extension Cord (Use Shortest Cord Possible)

Tables and guidelines for selecting appropriate extension cords based on load and length.

Section 10 - Parts List

Figure 10-1. Main Assembly

Exploded view of the main assembly with numbered parts.

Figure 10-2. Panel, Front w;Components

Detailed view of the front panel components and their part numbers.

Figure 10-3. Generator

Exploded view of the generator assembly and its components.

Summary

Section 1 - Safety Precautions - Read Before Using

1-1. Symbol Usage

Explains the meaning of symbols used in the manual for safety warnings.

1-2. Arc Welding Hazards

Details hazards associated with arc welding processes and protective measures.

1-3. Engine Hazards

Outlines potential dangers related to the engine, fuel, and exhaust systems.

1-4. Additional Symbols For Installation, Operation, And Maintenance

Covers symbols for specific operational and maintenance hazards and precautions.

1-5. Principal Safety Standards

Lists key safety standards and codes relevant to welding equipment.

1-6. EMF Information

Discusses electromagnetic field effects and how to minimize exposure.

Section 2 - Definitions

2-1. Symbol Definitions

Provides a glossary of symbols used in the manual for clarity and understanding.

Section 3 - Specifications

3-1. Weld, Power, And Engine Specifications

Details technical specifications for welding output, auxiliary power, and engine.

3-2. Dimensions, Weights, And Operating Angles

Lists physical dimensions, weight, and safe operating angles for the unit.

3-3. Fuel Consumption

Provides data on the unit's fuel consumption rates under various operating conditions.

3-4. Auxiliary Power Curve

Illustrates the available auxiliary power output at different amperage levels.

3-5. Duty Cycle

Explains duty cycle percentages and their impact on unit performance and warranty.

3-6. Volt-Ampere Curves

Graphic representation of voltage and amperage output capabilities across different modes.

Section 4 - Installation

4-1. Installing Welding Generator

Step-by-step guide for physically installing the welding generator unit.

4-2. Engine Prestart Checks

Essential checks to perform on the engine before starting the unit.

4-3. Connecting The Battery

Instructions for properly connecting the unit's battery for operation.

4-4. Connecting To Weld Output Terminals

Guidance on connecting cables to the correct output terminals for welding.

4-5. Selecting Weld Cable Sizes

Table for choosing appropriate weld cable sizes based on amperage and length.

4-6. Remote 14 Receptacle Information

Details the function and pin configuration of the Remote 14 receptacle.

4-7. Adjusting MIG Weld Puddle Consistency

Procedures for fine-tuning MIG welding puddle characteristics for optimal welds.

Section 5 - Operating Welding Generator

5-1. Front Panel Controls

Explanation of the function of each control on the generator's front panel.

5-2. Remote Amperage;Voltage Control

How to connect and use optional remote controls for amperage and voltage adjustment.

Section 6 - Operating Auxiliary Equipment

6-1. Auxiliary Power Receptacles And Circuit Breakers

Information on using auxiliary power outlets and understanding circuit breakers.

Section 7 - Maintenance And Troubleshooting

7-1. Routine Maintenance

Schedule and procedures for regular maintenance tasks to ensure optimal performance.

7-2. Maintenance Label

Details found on the engine's maintenance label for quick reference.

7-3. Servicing Air Cleaner

Step-by-step guide for cleaning and maintaining the air cleaner element.

7-4. Servicing Optional Spark Arrestor

Instructions for inspecting and cleaning the optional spark arrestor.

7-5. Changing Engine Oil, Oil Filter, And Fuel Filter

Procedures for replacing engine oil, oil filter, and fuel filter.

7-6. Adjusting Engine Speed

How to adjust engine idle and weld/power speeds for proper operation.

7-7. Overload Protection

Explanation of overload protection features and circuit breaker reset procedures.

7-8. Troubleshooting

Guidance for diagnosing and resolving common welding and engine operational issues.

Section 8 - Electrical Diagram

Section 9 - Auxiliary Power Guidelines

9-1. Selecting Equipment

Advice on choosing auxiliary equipment compatible with the generator's output.

9-2. Grounding Generator To Truck Or Trailer Frame

Instructions for properly grounding the generator when mounted on a vehicle frame.

9-3. Grounding When Supplying Building Systems

Guidance on grounding the generator when connecting to building electrical systems.

9-4. How Much Power Does Equipment Require?

Explains how to calculate power requirements for connected equipment.

9-5. Approximate Power Requirements For Industrial Motors

Table listing typical power requirements for various industrial motors.

9-6. Approximate Power Requirements For Farm;Home Equipment

Table listing typical power requirements for farm and home equipment.

9-7. Approximate Power Requirements For Contractor Equipment

Table listing typical power requirements for contractor equipment.

9-8. Power Required To Start Motor

Explains how to determine the starting amperage needed for motors.

9-9. How Much Power Can Generator Supply?

Guidance on generator output limits and starting motor loads.

9-10. Typical Connections To Supply Standby Power

Diagrams and instructions for connecting the generator for standby power.

9-11. Selecting Extension Cord (Use Shortest Cord Possible)

Tables and guidelines for selecting appropriate extension cords based on load and length.

Section 10 - Parts List

Figure 10-1. Main Assembly

Exploded view of the main assembly with numbered parts.

Figure 10-2. Panel, Front w;Components

Detailed view of the front panel components and their part numbers.

Figure 10-3. Generator

Exploded view of the generator assembly and its components.

Miller Trailblazer 251 Specifications

General IconGeneral
Frequency60 Hz
Power Factor0.95
Efficiency85%
Fuel TypeGasoline
Input PhaseSingle/Three
EngineKohler CH
Fuel Tank Capacity12 gallons
Fuel Consumption1.5 gal/hr
Welding ProcessesStick, MIG, TIG
Welding Amperage Range40 - 250 A

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