Miller HJ134589 User manual

April

1978

FORM:

OM-457C

MODEL

Trailblazer

22G

OWN

ERS

MANUAL

ITIIIIER

MILLER

ELECTRIC

MFG.

CO.

718

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

54912

USA

Effective

With

Serial

No.

HJ134589

NWSA

CODE

NO. 4579

PRINTED

U.S.A.

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

20,

1978

a

This

warranty

supersedes

all

MILLER

warranties

and

clusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTYMiller

Electric

Mfg.

Co..

Apple-

Arc

welders,

power

sources,

and

components.

year

ton,

Wisconsin

warrants

Customer

that

all

new

and

unused

Original

main

power

rectifiers

years

Equipment

furnished

Miller

free

from

defect

(Labor



year

only)

workmanship

and

material

the

time

and

place

delivery

Miller.

warranty

made

Miller

with

All

welding

guns

and

feeder/guns

days

respect

engines,

trade

accessories

other

items

manu-

All

other

Millermatic

Feeders

year

factured

others.

Such

engines,

trade

accessories

and

other

provided

that

the

user

notifies

Miller

writing

within

thirty

items

are

sold

subject

the

warranties

their

respective

(30)

days

the

date

such

failure.

manufacturers,

any.

The

manufacturers

warranty

Replacement

repair

parts

exclusive

labor

days

engines

for

period

one

year.

MILLER

warranty

does

not

apply

components

having

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

normal

useful

life

less

than

one

(1)

year,

such

spot

HEREIN

AND ANY

IMPLIED

WARRANTY,

GUARANTY

welder

tips,

relay

and

contactor

points,

MILLERMATIC

REPRESENTATION

PERFORMANCE,

AND

parts

that

come

contact

with

the

welding

wire

including

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

nozzles

and

nozzle

insulators

where

failure

does

not

result

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

from

defect

workmanship

materiat.

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ANY

the

case

Millers

breach

warranty

any

other

IMPLIED

WARRANTY

MERCHANTABILITY

duty

with

respect

the

quality

any

goods,

the

exclusive

remedies

therefor

shall

be,

Millers

option,

(1)

repair

(2)

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

replacement

or,

where

authorized

writing

Miller

ANY

AND

ALL

EQUIPMENT

FURNISHED

appropriate

cases,

(3)

the

reasonable

cost

repair

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

replacement

authorized

Miller

service

station

(4)

payment

credit

for

the

purchase

price

(less

reasoi~able

EXCEPT AS

EXPRESSLY

PROVIDED

MILLER

depreciation

based

upon

actual

use)

upon

return

the

goods

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

Customers

risk

and

expense.

All

transactions

are

FOB.

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

Appleton.

Wisconsin.

Upon

receipt

notice

apparent

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

defect

failure,

Miller

shall

instruct

the

claimant

the

AND

EXPERIENCED

THE

USE

AND

MAINTENANCE

warranty

claim

procedures

followed.

WELDING

EQUIPMENT

AND

NOT,

FOR

CONSUMERS

matter

general

policy

only,

Miller

may

honor

CONSUMER

USE.

MILLER

WARRANTIES

NOT

original

users

warranty

claims

warranted

Equipment

EXTEND

TO,

AND

RESELLER

AUTHORIZED

the

event

failure

resulting

from

defect within

the

following

periods

from

the

date

delivery

Equipment

EXTEND

MILLERS

WARRANTIES

TO,

ANY

the

original

user:

CONSUMER.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

ex.cenXioi~s.tadata

aooearina

later

this

manual.

AMENDMENT

SECTION

INSTALLATION

Amend

Section

3-3.

EQUIPMENT

GROUNDING

TERMINAL

Normally

engine-driven

welding

generators

not

require

grounding.

However,

this

machine

has

auxiliary

power

plant

capability;

therefore,

grounding

the

frame

and

case

recommended.

Also,

unusual

circumstances

may

quire

machine

grounding.

For

these

reasons

convenient

grounding

terminal

provided

all

weld/power

units.

For

detailed

grounding

instructions

consult

your,

local

state

codes

and

the

latest

issue

the

National

Electrical

Code.

additional

information

regarding

your

particular

operating

circumstances

and/or

grounding

requirements

needed,

consult

qualified

electrician

your

dealer.

After

determining

the

extent

which

any

grounding

quirements

apply

your

particular

situation,

them

explicitly.

Circuit

Groundingl

Jumper

Lead

IShipped

Ungrounded)

AMENDMENT

SECTION

FUNCTION

GENERATOR

CONTROLS

Amend

Sections

5-1

and

5-9

Add

the

following

CAUTION

block

the

beginning

the

section

TC-000

680-B

Amend

Figure

3-3.

Power

Plant

Connections

Figure

3-3.

Power

Plant

Connections

CAUTION:

_______

The

auxiliary

power

capability

this

welding

generator

primarily

intended

for

use

with

portable

cord-

connected

accessory

equipment

(lights,

drills,

grinders,

etc.).

not

connect

this

unit

any

service

box,

swit

chboard,

panelboard,

other

equipment

normally

supplied

other

electrical

power

unless

proper

transfer

switch

and

grounding

procedure

employed

(see

Section

3-3

for

unit

grounding

information).

ALWAYS

consult

the

local

electric

utility,

local

and

state

codes,

and

the

latest

issue

the

National

Electrical

Code

for

proper

installation

pro

cedures.

Since

hazardous

voltages

are

present,

recommended

that the

installation

made

licensed

electri

clan

avoid

injury

damage

caused

improper

faulty

installation.

AMENDMENT

SECTION

FUNCTION

ENGINE

CONTROLS

Delete

Section

6-7.

ELECTRICAL

TACHOMETER

(OPTIONAL)

AMENDMENT

SECTION

SEQUENCE

OPERATION

Amend

Section

7-2.

POWER

PLANT

OPERATION

OM-457C

Page

CAUTION.:

Add

CAUTION

block

beginning

Section

The

weld

output

terminals

are

electrically

energized

when

the

engine

running.

Disconnect

the~

we/ding

cables

when

not

we/ding

and

not

touch

the

output

terminals

when

the

engine

running.

AMENDMENT

SECTION

ENGINE

MAINTENANCE

Amend

Section

9-3.

GOVERNOR

SERVICE

Weld

speed

this

engine

1850

rpm.

Amend

Section

9-4.

CARBURETOR

FLOAT

SETTING

Carburetor

Change

Effective

With

Serial

No.

HJ185451

I~1t~

not

bend,

twist,

apply

pressure

the

float

body.

The

float

body,

when

viewed from

the

free

end,

must

centered

between

and

right

angles

the

machined

surface,

and

must

move

freely

the

float

axle.

This

engine

equipped

with

Teledyne

Walbro

carburetor.

ensure

correct

fuel

level

the

float

chamber,

check

distance

(dimension

Figure

9-1)

from

top

float

machined

surface

throttle

body

(no

gasket)

with

throttle

body

inverted.

This

dimension

should

1-1/16

inches

plus

minus

.020

inch.

increase

decrease

distance

from

the

top

the

float

body

the

machined

surface,

use

long

nose

pliers

and

bend

the

float

lever

point

the

float

body.

Delete

Figure

9-2.

Carburetor

Float

Setting

Amend

Section

9-9.

IDLE

CONTROL/GOVERNOR

LINKAGE

ADJUSTMENT

(Figure

9-7)

Amend

Figure

9-7.

IDLE

CONTROL/GOVERNOR

LINKAGE

ADJUSTMENT

obtain

proper

engine

idle

and/or

weld

speed,

perform~

the

following

procedures:

0M-457C

Page

Figure

9-7.

Idle

Control/Governor

Linkage

Adjustment

TCO8O

511

IMPORTANT

CAUTION

IMPORTANT

Loosen

the

linkage

nuts

and

remove

the

hardware

(10)

securing

the

linkage

socket

(9)

the

governor.

Rotate

thelinkage

socket

(9)

until

the

throttle

stop

plate

(2)

about

1/32

inch

from

the

stop

(1).

clockwise

rotation

the

linkage

socket

(9)

will

shorten

the

governor

linkage

(7)

and

reduce

the

gap;

counterclockwise

rotation

the

linkage

socket

(9)

will

lengthen

the

governor

linkage

(7)

and

widen

the

gap.

(In

some

cases

may

necessary

adjust

the

linkage

itself

obtain

the

1/32

inch

gap

required.)

Tighten

the

linkage

socket

nuts

lock

the

position

the

linkage

sockets

9).

______________

Check

the

linkage

(7J

for

freedom

movement

throughout

its

entire

travel.

the

linkage

binding

due

the

linkage

socket

nuts

being

out

proper

alignment,

loosen

the

linkage

socket

nuts

and

rotate

the

sockets

slightly

until

unrestricted

movement

the

linkage

(7)

restored.

Tighten

the

linkage

socket

nuts

(6&8).

Ensure

that

body

limbs

are

clear

the

fan

and

the

vacuum

motor

unit

before

starting

working

the

engine.

-------

--------~

----

-:~-~

Recheck

all

adjustments

made

thus

far.

Place

the

IDLE

CONTROL

switch

the

LOCK

OUT

position.

Start

the

engine

and

allow

reach

normal

operating

temperature

(about

five

minutes).

Ensure

that

the

CHOKE

control

pushed

fully

this

time.

Pull

the

arm

(3)

toward

the

front

the

welding

generator

the

idle

position.

Maintain

pressure

the

arm

(3)

butt

against

the

idle

screw

(4)

throughout

the

following

adjustments:

Rotate

the

idle

screw

(4)

obtain

550

rpm.

Clockwise

rotation

the

screw

(4)

will

increase

engine

rpm,

whereas

counterclockwise

rotation

the

screw

(4)

will

decrease

engine

rpm.

Rotate

the

idle

mixture

adjustment

screw

(20)

counterclockwise

until

the

engine

begins

falter

roll;

then

rotate

the

screw

(20)

clockwise

until

the

engine

operates

smoothly.

Rotating

the

screw

(20)

clockwise

restricts

the

fuel

flow,

making

the

air-fuel

mixture

leaner.

Rotating

the

screw

(20)

counterclockwise

admits

fuel,

making

the

air-fuel

mixture

richer.

Ensure

that

the

vacuum

motor

idle

screw

(16)

butts

against

the

vacuum

motor

unit

mounting

plate

BEFORE

the

throttle

stop

plate

(2)

butts

against

the

idle

screw

(4)

prior

p/acing

the

IDLE

CONTROL

switch

the

AUTOMA

TIC

IDLE

position.

obtain

this

condition

may

necessary

adjust

screw

(16).

Check

manually

pivoting

the

vacuum

motor

arm

(17)

until

screw

(16)

butts

against

the

mounting

plate.

Place

the

IDLE

CONTROL

switch

the

AUTOMATIC

IDLE

position.

Operation

the

idling

device

automatic

when

the

IDLE

CONTROL

switch

the

AUTOMATIC

IDLE

position.

When

the

engine

running,

engine

rpm

will

remain

idle

until

arc

established,

which

time the

engine

immediately

comes

weld

rpm.

When

the

arc

broken,

time

delay

will

exist

before

the

engine

begins

return

idle

rpm.

The

length

this

time

delay

controlled

the

setting

the

time-delay

screw

A

Figure

9-7.

the

engine

does

not

idle

rpm

after

about

ten

seconds,

adjust

the

time-delay

screw

(A)

for

the

desired

time

delay.

This

screw

located

the

vacuum

line

fitting

going

into

the

intake

manifold

the

engine.~

When

the

engine

has

gone

idle

rpm,

adjust

screw

(16)

until

1200

rpm

obtained.

I~EIi11~

not

readjust

the

idle

rpm

screw

(4)

when

adjusting

the

vacuum

motor

idle

rpm.



______________

Check

the

linkage

(19)

for

freedom

movement

throughout

its

entire

travel.

the

linkage

binding

due

the

linkage

socket

(18)

being

outof

proper

alignment

with

the

fixed

end,

adjust

the

tength

the

linkage.

will-

then

necessary

readjust

the

vacuum

motor

idle

screw

(16)

and

repeat

Steps

and

Is~..tU.I

Ensure

that

body

limbs

are

clear

the

fan

and

the

vacuum

motor

unit

before

working

the

engine.

Place

the

IDLE

CONTROL

switch

the

LOCK

OUT

position.

Loosen

the

governor

speed

adjusting

screw

secur

ing

nut

(11).

Adjust

the.governor

speed

adjustment

screw

(12)

until

high

idle

rpm

1850

obtained.

Tighten

the

securing

nut

(11)

maintain

the

governor

speed

setting.

Check

the

governor

engine

regulation

applying

and

removing

the

engine

load.

governor

sensitivity

adjust

ment

deemed

necessary,

loosen

one

the

two

locking

nuts

(13)

and

proceed

with

the

following

instructions:

REGULATION

RANGE

TOO

BROAD

Decrease

the

governor

spring

(15)

tension

sliding

the

sen

sitivity

adjustment

screw

(14)

inward.

REGULATION

RANGE

TOO

NARROW

Increase

the

governor

spring

(15)

tension

sliding

the

sen

sitivity

adjustment

screw

(14)

outward.

ENGINE

SURGES

(HUNTS)

UNDER

LOAD

Increase

the

governor

spring

(15)

tension

sliding

the

sen

sitivity

adjustment

screw

(14)

outward.

Tighten

the

two

locking

nuts

(13)

maintain

the

desired

governor

sensitivity.

Readjust

the

governor

sensitivity

repeating

Step

)

Whenever

the

governor

sensitivity

(Step

adjusted,

the

governor

speed

(Step

MUST

readjusted.

Whenever

the

governor

speed

(Step

adjusted,

the

governor

sensitivfty

(Step

MAY

need

readjustment.

Amend

Section

9-10.

HIGH

ALTITUDE

CARBURETOR

MODIFICATION

(Optional)

(Figure

9-7)

The

Teledyne

Walbro

carburetor

can

equipped

with

adjustable

main

jet

for

high-altitude

operation

(above

4000

ft.).

Minor

adjustment

will

necessary

for

proper

operation

particular

altitude.

Whenever

carburetor

adjust

ment

deemed

necessary,

see

Figure

9-7

and

proceed

follows:

Loosen

the

main

adjustment

screw

locking

nut

(22).

Apply

near-full

engine

load

the

welding

generator.

Rotate

the

main

adjustment

screw

(21)

clockwise

until

the

engine

begins

falter

and

lose

RPM.

Rotate

the

main

adjustment

screw

(21)

counterclockwise

until

the

engine

operates

smoothly;

then

continue

counterclockwise

rotation

1/4

turn.

Rotating

the

screw

(21)

clockwise

restricts

the

fuel

flow,

making

the

air-fuel

mixture

leaner.

Rotating

the

screw

(21)

counterclockwise

admits

fuel,

making

the

air-fuel

mixture

richer.

Remove

the

engine

load.

Tighten

the

locking

nut

(22).

IMPORTANT

Restricting

the

fuel

flow

the

point

where

the

mixture

too

lean

will-cause valve

burning.

Delete

Figure

9-8.

High-Altitude

Carburetor

Adjustment

AMENDMENT

SECTION

TROUBLESHOOTING

C

o~a

UETEA

(Q~T

C%AL)

OM-457C

PageD

Figure

10-1.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

HJ211479

Amend

Figure

10-1.

Circuit

Diagram

EOWE3

,,_-_~___

5EU~A4~.

GRCcu~UIC

S~3ED

E~E1r

*.OTE

SIAAA

AWE

A1.DWELE!R

jESUS

r.._77

;scfi

127

J,~2

EOW

REAR

VIEW

CAUTION

c0)

-~<

CA~.GE-3VER

~7

NCI.~C:p~V

acE

~OLr

Circuit

Diagram

No.

B-081

027

)tem

Dia.

Part

No.

Listed

No.

Mkgs.

Parts

List

010318

053724

017421

036259

VS1

025932

OlO

493

053

359

Replaced

With

Part

No.

015

602

053

966

049685

036

377

024

017

Deleted

032

936

080

487

601158

079

486

010 014

010

891

030

170

011

609

Quantity

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-457C

Page

Description

Page

TAC

032

936

032

936

039

269

100

146

S2,5

VALVE,

shut

off

w/strainer

fuel

GUARD,

fan

CATCH,

door

REACTOR

SUPPRESSOR,

0.75

volts

(Eff

with

S/N

HK311202)

METER

(dia.

mkg.

changed)

FUSE

BOX

(Eff

with

S/N

HJ211479)

BLANK,

snap

7/8

(Eff

with

S/N

HJ21

1479)

COVER,

junction

box

(Eff

with

S/N

HJ21

1479)

CLAMP,

steel

cushion

3/4

dia

13/64

hole

(Eff

with

S/N

HJ21

1479)

BLANK,

snap

inch

dia

(Eff

with

S/N

HJ211479)

BUSHING,snapin3/4IDx1

SWITCH,

toggle

SPDT

amp

125

volts

Section

No.

TABLE

CONTENTS

Page

No.

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

SECTION

2

INTRODUCTION

2-1.

2-4.

General

Receiving-Handling

Description

Safety

SECTION

3

INSTALLATION

3-1.

3-2.

3-4.

4-1.

5-1.

5-7.

5-8.

5-9.

6-1.

6-4.

Location

Weld

Output

Connections

Equipment

Grounding

Terminal

Remote

Amperage

Control

Connections

6677

-1.

Introduction

General

Precautions

Arc

Welding

Standards

Booklet

Index

120/240

Volts

Terminals..

SECTION

4

ENGINE

PREPARATION

Lubrication

Coolant

System

Preparing

New

Battery

For

Service

Air

Cleaner

Fuel

SECTION



FUNCTION

GENERATOR

CONTROLS

120

Volts

Receptacle

Range

Switch

Fine

Amperage

Control

Remote

Amperage

Control

Volt-Ampere

Curves

Duty

Cycle

Polarity

Switch

Meters

240

Volts

Duplex

Receptacle

SECTION

6

FUNCTION

ENGINE

CONTROLS

Choke

Control

Start

Push

Button

And

Switch

Idle

Control

Switch

Engine

Ammeter

Temperature

Gauge

Oil

Pressure

Gauge

Electrical

Tachometer

Total

Hour

Meter

SECTION



SEQUENCE

OPERATION

Sheilded

Metal-Arc

(SMAW)

Welding

Power

Plant

Operation

Starting

The

Engine

Shut

Down

Section

No.

Page

No.

SECTION



GENERATOR

MAINTENANCE

8-1.

General

Collector

Ring

Brushes

Welding

Cables

SECTION

9

ENGINE

MAINTENANCE

9-1.

Lubrication

Coolant

System

9-3.

Governor

Service

Carburetor

Float

Setting

Vacuum

Circuit

Air

Filter

Idle

Control

Time

Delay

Adjustment

Carburetor

Air

Temperature

Selector

Air

Cleaner

Service

Idle

Control/Governor

Linkage

Adjustment

9.10.

High

Altitude

Carburetor

Modification

9.11.

Key

Type

Ignition

Switch

Lubrication

9-12.

Spark

Arrestor

SECTION

10

TROUBLESHOOTING

PARTS

LIST

This manual suits for next models

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