Miller HJ134589 User manual

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

LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
20,
1978
a
This
warranty
supersedes
all
previous
MILLER
warranties and is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller Electric
Mfg.
Co..
Apple-
1.
Arc
welders,
power
sources,
and
components.
.
1
year
ton,
Wisconsin
warrants
to
Customer
that
all
new and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
(Labor

1
year
only)
workmanship
and material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller with
3.
All
welding
guns
and
feeder/guns
90
days
respect
to
engines,
trade
accessories
or
other items
manu-
4. All
other
Millermatic
Feeders
1
year
factured
by
others.
Such
engines,
trade
accessories
and
other
provided
that the
user so
notifies
Miller
in
writing
within
thirty
items
are
sold
subject
to
the
warranties
of
their
respective
(30)
days
of the
date
of
such failure.
manufacturers,
if
any.
The
manufacturers
warranty
on
5.
Replacement
or
repair
parts
exclusive
of labor
60
days
engines
is
for
a
period
of
one
year.
MILLER
warranty
does
not
apply
to
components
having
ANY EXPRESS WARRANTY
NOT
PROVIDED
normal
useful
life
of less than
one
(1)
year,
such
as
spot
HEREIN
AND ANY IMPLIED
WARRANTY,
GUARANTY
welder
tips,
relay
and
contactor
points,
MILLERMATIC
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
parts
that
come
in
contact
with the
welding
wire
including
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
nozzles
and
nozzle
insulators
where
failure
does
not
result
BUT
FOR THIS
PROVISION,
MIGHT ARISE
BY
from defect
in
workmanship
or
materiat.
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE OR COURSE
OF
DEALING,
INCLUDING ANY
In
the
case
of
Millers breach of
warranty
or
any
other
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
FITNESS FOR PARTICULAR
PURPOSE,
WITH
RESPECT
replacement
or,
where
authorized
in
writing
by
Miller
in
TO
ANY AND
ALL
EQUIPMENT
FURNISHED
BY
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
replacement
at
an
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase price
(less
reasoi~able
EXCEPT AS
EXPRESSLY
PROVIDED BY
MILLER
IN
depreciation
based
upon
actual
use)
upon
return
of
the
goods
WRITING,
MILLER
PRODUCTS
ARE
INTENDED FOR
at
Customers risk and
expense.
All
transactions
are
FOB.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
$
Appleton.
Wisconsin.
Upon receipt
of
notice
of
apparent
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
defect
or failure,
Miller shall
instruct the
claimant
on
the
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
warranty
claim
procedures
to
be followed.
OF WELDING
EQUIPMENT
AND
NOT,
FOR
CONSUMERS
As
a
matter
of
general
policy only,
Miller
may
honor
an
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
original
users
warranty
claims
on
warranted
Equipment
in
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED TO
the
event
of failure
resulting
from
a
defect within the
following
periods
from
the
date
of
delivery
of
Equipment
to
EXTEND
MILLERS
WARRANTIES
TO,
ANY
the
original
user:
CONSUMER.

ERRATA
SHEET
After this manual
was
printed,
refinements
in
equipment
design
occurred.
This sheet
lists
ex.cenXioi~s.tadata aooearina
later in
this
manual.
AMENDMENT
TO SECTION
3
INSTALLATION
Amend Section 3-3.
EQUIPMENT
GROUNDING
TERMINAL
Normally engine-driven welding
generators
do
not
require
grounding.
However,
this
machine has
auxiliary
power
plant
capability;
therefore,
grounding
of
the
frame
and
case
is
recommended.
Also,
unusual circumstances
may
re
quire
machine
grounding.
For
these
reasons
a
convenient
grounding
terminal
is
provided
on
all
weld/power
units.
For
detailed
grounding
instructions
consult
your,
local
or state
codes
and
the
latest issue of the National
Electrical
Code.
If additional information
regarding
your
particular operating
circumstances
and/or
grounding
requirements
is
needed,
consult
a
qualified
electrician
or
your
dealer.
After
determining
the
extent
to
which
any
grounding
re
quirements
apply
to
your
particular
situation,
follow
them
explicitly.
Circuit
Groundingl
Jumper
Lead
IShipped
Ungrounded)
AMENDMENT
TO
SECTION 5-
FUNCTION
OF GENERATOR
CONTROLS
Amend
Sections
5-1 and 5-9
Add
the
following
CAUTION
block
at
the
beginning
of
the
section
TC-000
680-B
Amend
Figure
3-3.
Power
Plant
Connections
Figure
3-3. Power
Plant
Connections
CAUTION:
_______
The
auxiliary
power
capability
of
this
welding
generator
is
primarily
intended for
use
with
portable
cord-
connected
accessory
equipment
(lights,
drills,
grinders,
etc.).
Do
not
connect this
unit
to
any
service
box,
swit
chboard,
panelboard,
or
other
equipment normally
supplied by
other electrical
power
unless
a
proper
transfer switch
and
grounding
procedure
is
employed
(see
Section
3-3
for
unit
grounding
information).
ALWAYS
consult the
local
electric
utility,
local
and
state
codes,
and
the
latest
issue of the
National
Electrical Code
for
proper
installation
pro
cedures.
Since hazardous
voltages
are
present,
it
is recommended that the
installation
be
made
by
a
licensed
electri
-
clan
to
avoid
injury
or
damage
caused
by
improper
or
faulty
installation.
AMENDMENT TO
SECTION
6-
FUNCTION OF ENGINE
CONTROLS
Delete
Section
6-7.
ELECTRICAL
TACHOMETER
(OPTIONAL)
/
AMENDMENT TO
SECTION
7-
SEQUENCE
OF
OPERATION
Amend Section
7-2.
POWER
PLANT
OPERATION
OM-457C
Page
A

CAUTION.:
-
Add CAUTION
block
at
beginning
of Section
/
The
weld
output
terminals
are
electrically energized
when
the
engine
is
running.
Disconnect
the~
we/ding
cables
when
not
we/ding
and do
not
touch
the
output
terminals
when the
engine
is
running.
AMENDMENT
TO SECTION 9-
ENGINE
MAINTENANCE
Amend Section
9-3.
GOVERNOR
SERVICE
Weld
speed
of this
engine
is 1850
rpm.
Amend Section 9-4.
CARBURETOR
FLOAT SETTING
Carburetor
Change
Effective
With
Serial
No.
HJ185451
I~1t~
Do
not
bend,
twist,
or
apply
pressure
on
the
float
body.
The
float
body,
when viewed from the
free
end,
must
be
centered
between
and
at
right
angles
to
the
machined
surface,
and
must
move
freely
on
the float
axle.
This
engine
is
equipped
with
a
Teledyne
Walbro
carburetor.
To
ensure
correct
fuel
level
in the float
chamber,
check distance
(dimension
A,
Figure
9-1)
from
top
of float
to
machined
surface of
throttle
body
(no
gasket)
with
throttle
body
inverted.
This dimension should be
1-1/16
inches
plus
or
minus .020
inch.
To
increase
or
decrease
distance from
the
top
of
the float
body
to
the machined
surface,
use
a
long
nose
pliers
and bend
the
float
lever
at
a
point
close
to
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
To
obtain
proper
engine
idle
and/or
weld
speed,
perform~
the
following
procedures:
0M-457C
Page
B
Figure
9-7. Idle
Control/Governor
Linkage
Adjustment
TCO8O
511

IMPORTANT
CAUTION
IMPORTANT
IMPORTANT
1.
Loosen
the
linkage
nuts
(6
&
8)
and
remove
the
hardware
(10)
securing
the
linkage
socket
(9)
to
the
governor.
Rotate
thelinkage
socket
(9)
until the
throttle
stop
plate
(2)
is
about
1/32
inch
from
the
stop
(1).
A
clockwise
rotation
of the
linkage
socket
(9)
will shorten
the
governor
linkage
(7)
and
reduce
the
gap;
a
counterclockwise
rotation
of
the
linkage
socket
(9)
will
lengthen
the
governor
linkage
(7)
and
widen
the
gap.
(In
some
cases
it
may
be
necessary
to
adjust
the
linkage
itself
to
obtain
the
1/32
inch
gap
required.)
Tighten
the
linkage
socket
nuts
(6
&
8)
to
lock the
position
of
the
linkage
sockets
(5
&
9).
______________
Check
the
linkage
(7J
for freedom
of
movement
throughout
its
entire
travel. If the
linkage
is
binding
due
to
the
linkage
socket
nuts
(5
&
9)
being
out
of
proper
alignment,
loosen
the
linkage
socket
nuts
(6
&
8)
and
rotate
the
sockets
(5
&
9)
slightly
until unrestricted
movement
of the
linkage
(7)
is restored.
Tighten
the
linkage
socket
nuts
(6&8).
Ensure
that
body
limbs
are
clear
of
the
fan and the
vacuum
motor
unit before
starting
or
working
on
the
~.
engine.
-------
--------~
---- -
-
-:~-~
-
2. Recheck
all
adjustments
made
thus
far.
Place
the
IDLE
CONTROL switch
in the
LOCK OUT
position.
Start
the
engine
and
allow
it
to
reach normal
operating
temperature
(about
five
minutes).
Ensure
that the
CHOKE
control
is
pushed
fully
in
at
this time.
-
3.
Pull
the
arm (3)
toward
the front of
the
welding
generator
to
the
idle
position.
Maintain
pressure
on
the
arm
(3)
to
butt
against
the
idle
screw
(4)
throughout
the
following
adjustments:
A. Rotate the
idle
screw (4)
to
obtain 550
rpm.
Clockwise
rotation
of the
screw
(4)
will
increase
engine
rpm,
whereas
counterclockwise rotation of the
screw (4)
will
decrease
engine
rpm.
B.
Rotate the idle
mixture
adjustment
screw
(20)
counterclockwise
until the
engine
begins
to
falter
or
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
more
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
to
p/acing
the
IDLE
CONTROL
switch
in
the
AUTOMA TIC
IDLE
position.
To
obtain
this condition it
may
be
necessary
to
adjust
screw
(16).
Check
by
manually
pivoting
the
vacuum
motor
arm (17)
until
screw (16)
butts
against
the
mounting
plate.
4.
Place the
IDLE
CONTROL
switch
in
the
AUTOMATIC
IDLE
position.
Operation
of the
idling
device
is
automatic
when
the
IDLE
CONTROL
switch
is in the
AUTOMATIC
IDLE
position.
When
the
engine
is
running,
engine
rpm
will
remain
at
idle
until
an arc
is
established,
at
which time the
engine
immediately
comes
up
to
weld
rpm.
When
the
arc
is
broken,
a
time
delay
will exist before
the
engine
begins
to
return
to
idle
rpm.
The
length
of
this
time
delay
is
controlled
by
the
setting
of the
time-delay
screw
A
in
Figure
9-7.
If the
engine
does
not
go
to
idle
rpm
after
about
ten
seconds,
adjust
the
time-delay
screw
(A)
for the
desired
time
delay.
This
screw
is located
on
the
vacuum
line
fitting going
into
the intake
manifold of the
engine.~
5. When
the
engine
has
gone
to
idle
rpm,
adjust
screw
(16)
until
1200
rpm
is
obtained.
I~EIi11~
Do
not
readjust
the idle
rpm
screw
(4)
when
adjusting
the
vacuum
motor
idle
rpm.

-
______________
Check
the
linkage
(19)
for
freedom
of movement
throughout
its
entire
travel. If
the
linkage
is
binding
due
to
the
linkage
socket
(18)
being
outof
proper
alignment
with
the fixed
end,
adjust
the
tength
of the
linkage.
It will-
then be
necessary
to
readjust
the
vacuum
motor
idle
screw
(16)
and
repeat
Steps
4
and
5.
Is~..tU.I
I
~ ~
Ensure
that
body
limbs
are
clear
of
the fan and the
vacuum
motor
unit
before
working
on
the
engine.
6. Place
the
IDLE
CONTROL
switch
in
the
LOCK
OUT
position.
Loosen
the
governor
speed
adjusting
screw
secur
ing
nut
(11).
Adjust
the.governor
speed adjustment
screw
(12)
until
a
high
idle
rpm
of
1850
is
obtained.
Tighten
the
securing
nut
(11)
to
maintain
the
governor
speed
setting.
7.
Check the
governor
engine
regulation
by
applying
and
removing
the
engine
load.
If
a
governor
sensitivity
adjust
ment
is
deemed
necessary,
loosen
one
of
the
two
locking
nuts
(13)
and
proceed
with the
following
instructions:
A.
IF
REGULATION RANGE
IS TOO
BROAD
-
Decrease
the
governor
spring
(15)
tension
by sliding
the
sen
sitivity adjustment
screw
(14)
inward.
B.
IF
REGULATION
RANGE
IS
TOO
NARROW
-
Increase the
governor
spring
(15)
tension
by sliding
the
sen
sitivity
adjustment
screw
(14)
outward.
C.
IF ENGINE
SURGES
(HUNTS)
UNDER LOAD
Increase
the
governor
spring
(15)
tension
by sliding
the
sen
sitivity
adjustment
screw
(14)
outward.
-~
-

8.
Tighten
the
two
locking
nuts
(13)
to
maintain
the
desired
governor
sensitivity.
Readjust
the
governor
sensitivity
by repeating
Step
7.
) 1~
Whenever
the
governor
sensitivity (Step
7)
is
adjusted,
the
governor
speed
(Step
6)
MUST be
readjusted.
Whenever
the
governor
speed
(Step
61
is
adjusted,
the
governor
sensitivfty
(Step
71
MAY
need
readjustment.
Amend
Section 9-10. HIGH
ALTITUDE
CARBURETOR
MODIFICATION
(Optional)
(Figure
9-7)
The
Teledyne
Walbro carburetor
can
be
equipped
with
an
adjustable
main
jet
for
high-altitude
operation
(above
4000
ft.).
Minor
adjustment
will be
necessary
for
proper
operation
at
a
particular
altitude. Whenever
a
carburetor
adjust
ment
is deemed
necessary,
see
Figure
9-7
and
proceed
as
follows:
Loosen
the main
adjustment
screw
locking
nut
(22).
Apply
a
near-full
engine
load
to
the
welding
generator.
Rotate
the
main
adjustment
screw
(21)
clockwise until the
engine begins
to
falter and
lose
RPM.
Rotate the
main
adjustment
screw
(21)
counterclockwise until the
engine
operates
smoothly;
then continue counterclockwise rotation of
1/4
turn.
Rotating
the
screw
(21)
clockwise
restricts
the
fuel
flow,
making
the
air-fuel
mixture leaner.
Rotating
the
screw
(21)
counterclockwise admits
more
fuel,
making
the
air-fuel
mixture richer. Remove the
engine
load.
Tighten
the
locking
nut
(22).
IMPORTANT
Restricting
the fuel flow
to
the
point
where the
mixture is
too
lean will-cause valve
burning.
Delete
Figure
9-8.
High-Altitude
Carburetor
Adjustment
AMENDMENT TO SECTION 10
-
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
AC
EOWE3
,,_-_~___
5EU~A4~. GRCcu~UIC
~
S~3ED
E~E1r
*.OTE ~ SIAAA ~ AE
AWE
A1.DWELE!R
jESUS
72
33
r.._77 ~
;scfi -~
~
127
J,~2
24
23
EOW
REAR VIEW
CAUTION
I
I
I
c0)
~
-~<
CA~.GE-3VER
I
~
~7
I
I
NCI.~C:p~V
acE
~OLr
I
If
-
/
Circuit
Diagram
No.
B-081 027

)tem
Dia.
Part
No.
Listed
-
No.
Mkgs.
In Parts
List
6
010318
33
053724
53
017421
77
Zi
036259
80
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
1
2
2
1
1
1
1
2
1
1
1
1
2
BE SURE
TO
PROVIDE MODEL
AND
SERIAL NUMBERS WHEN
ORDERING
REPLACEMENT PARTS.
OM-457C
Page
E
Description
Page
4
Page
5
97
TAC
HM
032
936
032
936
039
269
100
146
S2,5
VALVE,
shut
-
off
w/strainer
-
fuel
GUARD,
fan
CATCH,
door
REACTOR
SUPPRESSOR,
0.75
uf
65
volts
ac (Eff
with
S/N
HK311202)
METER
(dia.
mkg.
changed)
FUSE BOX
(Eff
with
S/N
HJ211479)
BLANK,
snap
-
in
7/8
(Eff
with
S/N
HJ21
1479)
COVER,
junction
box
(Eff
with
S/N
HJ21
1479)
CLAMP,
steel
-
cushion 3/4
dia
x
13/64
hole
(Eff
with
S/N
HJ21
1479)
BLANK,
snap
-
in 1 inch
dia
(Eff
with
S/N
HJ211479)
BUSHING,snapin3/4IDx1
SWITCH,
toggle
SPDT
15
amp
125
volts

p.

Section No.
TABLE
OF CONTENTS
Page
No.
SECTION
1

SAFETY RULES FOR
OPERATION
OF ARC WELDING
POWER SOURCE
SECTION
2
INTRODUCTION
2-1.
2
-
2.
2
-
3.
2-4.
General
Receiving-Handling
Description
Safety
SECTION
3
INSTALLATION
3-1.
3-2.
3
-
3.
3-4.
4-1.
4
-
2.
4
-
3.
4
-
4.
4
-
5.
5-1.
5
-
2.
5
-
3.
5
-
4.
5
-
5.
5
-
6.
5-7.
5-8.
5-9.
6-1.
6
-
2.
6
-
3.
6-4.
6
-
5.
6
-
6.
6
-
7.
6
-
8.
7- 1.
7
-
2.
7
-
3.
7
-
4.
Location
Weld
Output
Connections
Equipment
Grounding
Terminal
Remote
Amperage
Control
Connections
6677
7
8
8
8
9
9
10
10
10
10
10
11
11
11
11
12
12
12
12
12
12
12
12
13
13
13
13
1 -1.
1
-
2.
1
-
3.
1
-
4.
Introduction
General Precautions
Arc
Welding
Standards
Booklet
Index
1
3
4
5
5
5
5
3- 5.
120/240
Volts AC
Terminals..
SECTION
4
ENGINE
PREPARATION
Lubrication
Coolant
System
Preparing
New
Battery
For Service
Air
Cleaner
Fuel
SECTION
5

FUNCTION
OF
GENERATOR
CONTROLS
120
Volts AC
Receptacle
Range
Switch
Fine
Amperage
Control
Remote
Amperage
Control
Volt-Ampere
Curves
Duty
Cycle
Polarity
Switch
Meters
240 Volts AC
Duplex
Receptacle
SECTION
6 FUNCTION
OF
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
7

SEQUENCE OF OPERATION
Sheilded Metal-Arc
(SMAW)
Welding
Power
Plant
Operation
Starting
The
Engine
Engine
Shut
Down

Section No.
Page
No.
SECTION
8

GENERATOR
MAINTENANCE
8-1. General
14
8
-
2.
Collector
Ring
Brushes
14
8-
3.
Welding
Cables
14
SECTION
9
ENGINE
MAINTENANCE
9-1.
Lubrication
14
9~ 2.
Coolant
System
14
9-3. Governor Service
15
9.
4.
Carburetor
Float
Setting
15
9-
5. Vacuum
Circuit
Air
Filter
15
9.
6.
Idle
Control
Time
Delay
Adjustment
15
9-
7.
Carburetor
Air
Temperature
Selector
15
9- 8. Air Cleaner
Service
16
9-
9.
Idle
Control/Governor
Linkage
Adjustment
17
9.10.
High
Altitude Carburetor
Modification 18
9.11.
Key
Type
Ignition
Switch Lubrication
18
9-12.
Spark
Arrestor 18
SECTION
10
TROUBLESHOOTING
PARTS LIST