Miller Electric Trailblazer Pro 350 D User manual

Low noise operation allows for better
work site communication and safety.
72 db @ 7 m (no load—idle),
78 db @ 7 m (full load—high speed).
Processes
MIG (GMAW)
Flux Cored (FCAW)
Stick (SMAW)
TIG (GTAW)
Air Carbon Arc (CAC-A)
Cutting and Gouging
thru 1/4 in Carbons
Air Plasma Cutting
and Gouging with Optional
Spectrum Models
Output Range CC/DC: 20–350 A
CV/DC: 10–34 V
CC/AC: 35–250 A
Weld Output Rated at 104˚ F (40˚ C)
CC/DC and CV/DC: 300 A at 32 VDC, 100% Duty Cycle
350 A at 28 VDC, 60% Duty Cycle
CC/AC: 200 A at 25 VAC, 60% Duty Cycle
Generator Power Rated at 104˚ F (40˚ C)
12,000 watts continuous
Weight Net: 998 lb (453 kg)
Quick
Specs
Trailblazer®Pro 350 D Diesel Engine-Driven
Welder/Generator
Issued March 2006 • Index No. ED/4.65
The professional welder’s choice with higher outputs is
designed to deliver the best arc performance with enough
weld power to dominate larger diameter flux cored wires
and air carbon arc gouging thru 1/4 in carbons.
Weld at Idle™—lock in idle and weld in
DC up to 180 A.
12,000 watts of generator power is
regulated to provide constant, strong
power and very good motor starting
characteristics. Power is independent
of weld control settings so that the
correct voltage is available at all times.
Even better weld performance
with an arc that dominates the
competition. In Stick mode, you
get a smooth E7018 and a great
E6010 arc with Arc-Drive and
Hot Start™standard. Great
MIG/FCAW arc and machine idles
with feeders hooked up. More
stable AC TIG and excellent starts
in DC scratch start TIG.
The Power of Blue® .
Welder/generator is warranted for 3 years, parts and labor.
Engine is warranted separately by the engine manufacturer.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
Industrial Applications
Mechanical Contractors
Rig Owners
Structural Steel Work
Process Plant Piping
Fabrication
With a compact and lightweight
design at only 998 lb, a smaller
truck can be used, and related
transportation costs will be reduced.
Low height allows the driver to see
over the machine when mounted
on a truck bed and the machine fits
sideways in a standard pickup.
Weld meters now standard.
Automatic Start at Idle™idles engine
immediately when started, extending
engine life and reducing
fuel consumption and noise.
Toolless top and side engine access
allows easy and faster maintenance
with little clearance space needed.
Toolless remote oil drain is standard.
Standard 14-pin receptacle easily
connects feeders or remote controls
for enhanced process operation.
Automatic idle in all processes,
including MIG/FCAW with feeders
to save fuel and reduce noise.
26 HP, 3-cylinder Kubota diesel
engine with its durable, proven
liquid-cooled design is the world
standard for small diesel engines.
Engine shutdowns standard.
Cold weather starting aids such as
standard glow plugs and block heater
ensure good starts in cold weather.
Strong 120/240 V power while welding
to run tools and inverter welders. See
page 3 of literature.

FUEL CONSUMPTION
DC POWER AMPS AT 100% DUTY CYCLE
POWER KVA AT 100% DUTY CYCLE
0 50 150100 200 250 300 400350
02146810
12
IDLE
LITERS/HR.
U.S. GAL/HR.
DC STICK
(LOW SPEED)
DC STICK/AUX POWER
(HIGH SPEED)
0.501.98
0.250.95
00
0.752.84
1.003.78
1.505.67
1.254.73
1.756.62
2.00
7.57
Welding
Mode
CC/DC
CV/DC
CC/AC
Weld Output Rated at
104˚ F (40˚ C)
300 A, 32 VDC, 100% Duty Cycle
350 A, 28 VDC, 60% Duty Cycle
200 A, 25 VAC, 60% Duty Cycle
Output
Range
20–350 A
10–34 V
35–250 A
Max. Open-Circuit
Voltage DC
80
50
70
CSA approved. *Net weight with 2 gal of fuel. Add 40 lb for shipping weight.
6
2
1
3
4
11
9
10
12
7
8
5
2
Control Panel
Weight*
Net: 998 lb
(453 kg)
Dimensions
H: 30 in (762 mm)
W: 24 in (610 mm)
D: 59-1/2 in (1511 mm)
Single-Phase Generator Power
Output Rated at 104˚ F (40˚ C)
12 kVA/KW, 120/240 VAC,
100/50 A, 60 Hz
Specifications (Subject to change without notice.)
1. Voltmeter
2. Ammeter
3. Process/Contactor Switch
4. Voltage/Amperage Adjustment Control
5. Voltage/Amperage Adjust Switch and
Remote 14 Receptacle
6. DC Polarity/AC Selector Switch
7. Fuel Gauge
8. Hour Meter
9. Engine Speed Switch
10. Glow Plug Switch
11. Engine Control Switch
12. 120/240 V Receptacles
Note: GFCIs are standard
Performance Data
FUEL CONSUMPTION DATA
• 13-gallon fuel capacity.
• Welding at 150 A at 40% duty cycle, uses only
.61 gallon per hour— over 20 hours of operation.
Engine Specifications (Subject to change without notice.)
Engine Brand
Kubota DH905
2-year limited
North American
Manufacturer
Warranty
Horsepower (HP)
26 at 3600 RPM
Weld Speed
3600 RPM
Idle Speed
2525 RPM
Type
3-cylinder,
industrial,
liquid-cooled
diesel
Fuel
Capacity
13 gal (49 L)
Oil
Capacity
5.4 qt (5.1 L)
High Coolant Temp/
Low Oil Pressure Shutdown
Standard

3
VOLT/AMP CURVES
MINIMUM AND MAXIMUM - STICK MODE
AMPERES
VOLTS
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600
DUTY CYCLE CHART
WELD AMPERES
% DUTY CYCLE
0 102030405060708090100
100
150
200
250
300
350
400
DC Weld
AC Weld
VOLT/AMP CURVES
MINIMUM AND MAXIMUM - MIG MODE
AMPERES
0 100 200 300 400 500 600
0
10
20
30
40
50
60
70
80
VOLTS
GENERATOR POWER CURVE
AC VOLTS
AC AMPERES IN 240V MODE
AC AMPERES IN 120V MODE
300
250
200
150
100
50
0
150
125
100
75
50
25
00 10203040506070 8090
0 20 40 60 80 100 120 140 160 180
SIMULTANEOUS WELDING
AND GENERATOR POWER
Weld
Current
(Amps) Watts
120V 1P
Receptacle
Amps
240V 1P
Receptacle
Amps
0
100
150
200
300
350
100
90
80
62
25
10
50
45
40
31
12
5
12,000
11,000
9,500
7,500
3,000
1,000
12 kW
Performance Data (continued)
All Trailblazers have 2 generators—
a 4-pole, 3-phase weld generator and a
strong power generator.
TRAILBLAZER ADVANTAGE: No interaction
between grinders, power tools, etc. and
the welding arc. Generator power is also
independent of weld control settings.
POWER IS IN THE NUMBERS
•Tested and rated at higher temperatures, 104˚ F (40˚ C), to ensure consistent operation in all climates.
•Patented generator control technology matches the generator’s output to engine horsepower providing maximum efficiency
and more weld output.
•The generator is voltage regulated to provide strong power while keeping the voltage 120/240 volts. This increases
tool/motor performance and tool/motor life.
StatorRotor

4
Genuine Miller Options
Lockable Flame Arrestor Fuel Cap
#043 947 Field
Spark Arrestor Kit #194 871 Field
Full KVA Plug Kit
#119 172 Field
240/120 VAC single-
phase, 50 amp plug
(NEMA 14-50P) to fit
full KVA receptacle.
Protective Cover
#195 125 Blue, with Miller logo
Attractive, waterproof cover resists stains
and mildew, and protects the finish of
your welder.
Multioperator
CST™280 #907 244
The CST 280 CC/DC power source can be
run off the machine’s generator to provide
two arcs with only one engine. At only 41 lb
(18.6 kg), it is portable enough to take
anywhere. See Lit. Index No. DC/29.55.
Plasma Cutters
Spectrum®625 #907 058
Economical plasma cutting system
rated to cut 7/8 in. See Lit. Index
No. PC/9.5.
Spectrum 2050 #903 777-01-2
Portable, easy-to-carry unit is an excellent
choice for cutting jobs up to 3/4 in. See Lit.
Index No. PC/7.0.
MIG/Flux Cored Welding
SuitCase™8VS Wire Feeder #194 890
SuitCase™X-TREME™12VS Wire Feeder
#195 500
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor
and gas valve. Require drive roll kit.
See Lit. Index No. M/6.4, M/6.41.
SuitCase™8RC Wire Feeder #194 938
SuitCase™12RC Wire Feeder #194 940
Lightweight, modular design and flexible
enough to run a variety of wires up to
.062 in diameter. Comes standard with
remote voltage control. See Lit. Index
No. M/6.5.
Genuine Miller Accessories

5
Genuine Miller Accessories (Continued)
MIG/Flux Cored Welding (Continued)
Spoolmatic®30A #130 831
A 1-lb, air-cooled spool gun that extends
the weld process range by adding a handy
portable system for small wire MIG. Rated
200 A at 100% duty cycle. Includes 30 ft
(9.1 m) cable assembly. WC Control
required. See Lit. Index No. M/1.5.
WC-24 Control #137 549
To be used with Spoolmatic 30A.
XR Wire Feeders and Guns
Push-pull system designed to handle
difficult-to-feed soft alloy wires such as
aluminum. See Lit. Index No. M/1.7.
MIG (GMAW)/Flux Cored (FCAW) Guns
Miller produces a complete line of
dependable MIG guns. Check literature
for complete details. See Lit. Index Nos.
AY/16.0 and AY/17.0.
Stick (SMAW) Welding
Weld Leads
#173 851 2/0, 350 A, 100% duty cycle,
50 ft (15.2 m) stinger, 50 ft (15.2 m)
work cable.
#043 952 2/0, 300 A, 100% duty cycle,
100 ft (30.5 m) stinger, 50 ft (15.2 m)
work cable.
TIG (GTAW) Welding
HF-251 Series
#042 388 HF-251D-1, 115 VAC
High-frequency arc starter and stabilizer.
See Accessory Literature, Index No. AY/5.0.
Remote Controls and Switches
RFCS-14 HD Foot Control #194 744
For all Miller solid-state power sources
after serial number JK674521. This new
design increases stability with a larger
base, and durability with a heavier cord.
Maximum flexibility is accomplished with a
reconfigurable cord that can exit the front,
back or either side of the pedal. Foot pedal
provides remote current and contactor
control. Includes 20 ft (6 m) cord and
14-pin plug.
RHC-14 Hand Control #129 340
Miniature hand control for remote current
and contactor control. Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes
20 ft (6 m) cord and 14-pin plug.
RCC-14 Remote Contactor and Current
Control #151 086
Rotary-motion fingertip control. Fastens to
TIG torch using two Velcro strips. Allows
complete current and contactor control at
operator’s fingertips. Includes 28 ft (8.5 m)
cord and plug.
Extension Cords for 14-Pin
Remote Controls
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
PRHC-14 Hand Control #195 511
For all solid-state power sources after
serial number JK674521. Complete current
or voltage control brings 120 volts GFCI
power to work area in a single cord.
Housed in a durable light aluminum case
and includes 125 ft (38 m) cord with plugs.