Miller Electric HJ134589 User Manual

April

1978

FORM:

OM-457C

Effective

Trailblazer

With

MODEL

Serial

22G

No.

HJ134589

OWN

ERS

MANUAL

MILLER

718S.BOUNDS

APPLETON,

NWSA

ELECTRIC

ST.

WI

CODE

PRINTED

IN

54912

NO.

P.O.

U.S.A.

4579

Box

USA

MFG.

1079

ITIIIIER

CO.

LIMITED

WARRANTY

$

LIMITED

Wisconsin

ton,

Equipment

workmanship

are

by

to

by

sold

engines,

delivery

respect

factured

items

manufacturers,

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engines

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MILLER

useful

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replacement

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defect

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original

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failure,

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user:

WARRANTYMiller

warrants

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4.

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days

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ANY

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BUT

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FITNESS

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MILLER

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USERS

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CONSUMER

EXTEND
EXTEND

CONSUMER.

1978

20,

warranties

expressed

welders,

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EXPRESS

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WARRANTY

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MILLER

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the

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COURSE

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WARRANTY

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implied.

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After

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AMENDMENT

manual

was

TO

printed,

SECTION

refinements

INSTALLATION

3

ERRATA

in

equipment

design

SHEET

occurred.

This

sheet

ex.cenXioi~s.tadata

lists

aooearina

later

in

Amend

Normally

plant

quire

For

Code.

needed,

Section

engine-driven

capability;

machine

detailed

If

additional

consult

quirements

Amend

Figure

3-3.

therefore,

grounding.

grounding

information

a

qualified

to

apply

3-3.

Power

EQUIPMENT

welding

grounding

For

instructions

particular

your

Plant

GROUNDING

generators

of

these

reasons

consult

regarding

electrician

situation,

Connections

the

or

your

your

TERMINAL

do

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frame

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your,

require

and

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local

particular

dealer.

follow

case

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state

operating

After

them

grounding.

recommended.

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grounding

terminal

codes

circumstances

determining

explicitly.

However,

the

and

the

this

Also,

is

provided

latest

and/or

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machine

unusual

circumstances

all

on

issueofthe

grounding

which

to

has

auxiliary

weld/power

National

requirements

grounding

any

power

re

may

units.

Electrical

is

re

Circuit

Jumper

IShipped

AMENDMENT

Amend

Add

CAUTION:

_______

connected

Sections

the

chboard,

and

grounding

electric
cedures.
clantoavoid

-

AMENDMENT

Delete

AMENDMENT

Amend

utility,

Section

Section

Groundingl

Lead

Ungrounded)

TO

SECTION

5-1

and

following

accessory

panelboard,

CAUTION

The

auxiliary

equipment

or

procedure

and

local

Since

hazardous

or

injury

SECTION

TO

6-7.

ELECTRICAL

SECTION

TO

POWER

7-2.

5-9

power

other

is

state

voltages

damage

FUNCTION

5-

blockatthe

capability

(lights,

equipment

employed

codes,

are

caused

6-

FUNCTION

TACHOMETER

SEQUENCE

7-

PLANT

Figure

beginning

of

drills,

normally

Section

(see

the

and

present,

improper

by

OPERATION

3-3.

Power

OF

GENERATOR

of

this

welding

grinders,

supplied

3-3

issueofthe

latest

is

recommended

it

or

OF

ENGINE

(OPTIONAL)

OF

OPERATION

Plant

the

section

generator

etc.).

by

for

unit

faulty

Connections

CONTROLS

is

Do

other

primarily

connect

not

electrical

grounding

National

that the

installation.

CONTROLS

/

intended

this

power

unless

information).

Electrical

Code

installation

unit

be

for

to

a

ALWAYS

for

made

use

any

proper

proper

by

with

portable

service

transfer

consult

installation

licensed

a

TC-000

box,

switch

the

electri

OM-457C

680-B

cord-

swit

local

pro

Page

A

Add

CAUTION

CAUTION.:

we/ding

cables

block

The

when

at

weld

not

beginning

output

we/ding

terminals

and

of

Section

are

do

not

/

electrically

touch

the

energized

output

when

terminals

when

the

engine

the

is

running.

engineisrunning.

Disconnect

-

the~

AMENDMENT

Amend

Weld

speed

Amend

Carburetor

I~1t~

be

must

This

engine

To

ensure

machined

minus

or

plus

a

Delete

Amend

Amend

To

long

obtain

nose

Figure

Section

of

Section

Change

Do

not

centered

is

correct

surface

pliers

Section

Figure

proper

TO

SECTION

GOVERNOR

9-3.

this

engine

9-4.

CARBURETOR

Effective

bend,

between

equipped

fuel

of

throttle

.020

inch.

and

9-2.

Carburetor

IDLE

9-9.

9-7.

IDLE

engine

9-

SERVICE

is

1850

rpm.

With

Serial

or

twist,

with

level

To

bend

apply

and

at

right

a

Teledyne

in

the

(no

body

increaseordecrease

float

the

Float

CONTROL/GOVERNOR

CONTROL/GOVERNOR

idle

and/or

ENGINE

FLOAT

No.

pressure

angles

Walbro

float

chamber,

gasket)

lever

Setting

weld

speed,

MAINTENANCE

SETTING

HJ185451

on

to

carburetor.

with

distance

at

a

point

perform~

the

float

the

machined

check
throttle

closetothe

LINKAGE

LINKAGE

body.

distance

body

from

ADJUSTMENT

the

The

surface,

(dimension

inverted.

top

float

of

the

ADJUSTMENT

following

float

body,

and

must

A,

This

dimension

the

float

body

body.

(Figure

procedures:

when

move

Figure

to

9-7)

viewed

freely

9-1)

should

the

machined

on

from

from

be

the

top

1-1/16

free

the

float

axle.

of

float

inches

surface,

end,

to

use

0M-457C

Page

TCO8O

511

9-7.

Idle

Figure

B

Control/Governor

Linkage

Adjustment

1.

Loosen
Rotate

rotation
rotationofthe

be
&

IMPORTANT

______________

due

the

the

to

sockets

(6&8).

CAUTION

engine.

2.

Recheck

engine

pushed

the

thelinkage

of

necessary

lock

to

8)

linkage

(5

and

fully

linkage

the

linkage

linkage

to

adjust

the

position

Check

socket

&

9)

slightly

Ensure

all

that

-------

adjustments

it

allow

in

at

nuts

socket

the

nuts

body

reach

to

this

&

(6

(9)

socket

socket

the

linkage

of

linkage

&

(5

until

unrestricted

limbs

--------~

made

normal

time.

8)

until

(9)

(9)

the

9)

and

remove

the

will

will

lengthen

itself

linkage

for

(7J

being

clear

are

----

far.

thus

operating

throttle

shorten

obtain

to

sockets

freedom

out

movement

of

-

Place

hardware

the

stop

the

governor

the

governor

the

(5&9).

of

movement

of

proper

fan

the

the

temperature

(10)

(2)

plate

inch

1/32

alignment,

of

the

linkage

and

the

-

CONTROL

IDLE

(about

securing

about

is

linkage

linkage

(7)

(7)

required.)

gap

throughout

loosen

is

(7)

-:~-~

switch

five

motor

minutes).

vacuum

the

linkage

inch

1/32

reduce

and

widen

and

its

entire

the

linkage

restored.

unit

in

from

the

the

Tighten

travel.Ifthe

socket

Tighten

before

-

the

LOCK

Ensure

socket

the

stop

gap;

(In

gap.

the

linkage

nuts

the

starting

OUT

that

the

the

to

(9)

counterclockwise

a

some

(1).

governor.

clockwise

A

cases

socket

is

linkage

&

(6

linkage

or

working

position.

CHOKE

-

and

8)

socket

binding

Start

control

it

nuts

rotate

nuts

on

may

the

the

(6

~.

is

3.

Pull
butt

A.

B.

IMPORTANT

BEFORE

AUTOMA

pivoting

Place

4.

when

will

the

delay

after

vacuum

5.

When

I~EIi11~

the

arm

(3)

against

Rotate

whereas

Rotate

rotate

restricts

more

the

TIC

the

the

the

remain

arc

is

about

Do

the

the

counterclockwise

the

the

the

fuel,

Ensure

throttle

IDLE

vacuum

IDLE

IDLE

idle

at

is

broken,

controlledbythe

ten

line

fitting

the

engine

not

readjust

idle

screw

mixture

the

screw

(20)

flow,

the

that

plate

toward

idle

idle

screw

fuel

making

stop

position.

motor

arm

CONTROL
CONTROL

until

an

time

a

seconds,

going

has

gone

the

front

of

(4)

throughout

obtain

to

(4)

rotationofthe

adjustment

clockwise

making

air-fuel

the

vacuum

butts

(2)

obtain

To

until

(17)

switchinthe

switch

is

arc

established,

will

delay
setting

adjust

into

idle

of

the

the

idle

to

rpm

the

welding

550

screw

until

the

air-fuel

mixture

motor

against

this

condition

screw

AUTOMATIC

isinthe

exist

before

the

time-delay

AUTOMATIC

time-delay

intake

manifoldofthe

adjust

rpm,

(4)

screw

generator

the

following

rpm.

screw

(20)

the

engine

mixture

richer.

idle

screw

the

idle

(16)

which

at

the

screw

screw

when

the

to

adjustments:

Clockwise

(4)

counterclockwise

screw

it

may

butts

time

engine

screw

(A)

rotation

will

decrease

operates

leaner.

butts

(16)

(4)

be

necessary

against

IDLE

position.

IDLE

the

begins

A

for

the

Rotating

priortop/acing

position.
engine

in

engine.~

until

(16)

adjusting

the

idle

position.

of

until

smoothly.

against

the

mounting

Operation

immediately

to

return

Figure

desired

1200

rpm

vacuum

the

engine

the

the

screw

the

to

adjust

When

If

9-7.

time

is

motor

Maintain

screw

(4)

rpm.

engine

Rotating

(20)

vacuum

the

IDLE

screw

plate.

of

the

the

engine

comes

idle

to

rpm.

the

engine

This

delay.

obtained.

idle

pressure

will

begins

the

on

increase

falter

to

screw

counterclockwise

unit

motor

mounting

CONTROL

Check

(16).

deviceisautomatic

idling

is

running,

weld

to

up

The

length

does

not

is

screw

-

rpm.



the

arm

engine

or

clockwise

(20)

switch

by

engine

rpm.

of

to

go

located

to

(3)

rpm,

then

roll;

admits

plate

in

the

manually

rpm

When

this

time

idle

rpm

the

on

IMPORTANT

______________

due

to

then

be

Is~..tU.I

6.

Place

ing

the

Check

7.

ment

A.

B.

C.

the

linkage

necessary

~

~

I

nut

Ensure

the

(11).

securing

the

is

deemed

IF

REGULATION

sitivity

IF

REGULATION

sitivity

IF

ENGINE

sitivity

Check

socket

to

readjust

that

CONTROL

IDLE

Adjust

nut

(11)

governor

necessary,

adjustment

adjustment

SURGES

adjustment

the

(18)

body

linkage

being

the

limbs

(19)

outof

vacuum

switch

the.governor

maintain

to

RANGE

screw

RANGE

screw

(HUNTS)

screw

regulation

loosen

IS

(14)

IS

(14)

(14)

engine

for

proper

clear

are

the

in

speed

the

one

TOO

inward.

TOO

outward.

UNDER

outward.

freedom

alignment

idle

motor

of

the

LOCK

adjustment

governor

by

applying

of

the

two

BROAD

NARROW

LOAD

-~

of

screw

fan

OUT

speed

-

Decrease

-

movement

and

with

(16)

and

the

position.

screw

setting.

removing

locking

Increase

Increase

throughout

the

fixed

and

vacuum

Loosen

until

(12)

the

nuts

(13)

the

governor

the

governor

the

governor

end,

repeat

the

a

engine

and

its

adjust

Steps

motor

governor

high

proceed

spring

spring

spring

entire

unit

idle

load.

4

rpm

with

(15)

travel.

the

and

before

speed

of

If

a

(15)

(15)

-

If

tength

5.

working

adjusting

1850

governor

the

following

tension

tension

tension

the

linkageisbinding

of

the

linkage.

the

on

screw

is

obtained.

sensitivity

instructions:

by

sliding

by

sliding

by

the

the

the

sliding

It

will-

engine.

secur

Tighten

adjust

sen

sen

sen

8.

Tighten

by

repeating

the

two

Step

locking

7.

nuts

(13)

to

maintain

the

desired

governor

sensitivity.

Readjust

the

governor

sensitivity

)

Whenever

Amend

The

ft.).

ment

Loosen

main

screw

Rotating

Whenever

1~

the

Section

Teledyne

Minor

adjustment

is

deemed

the

main

adjustment

counterclockwise

(21)

the

screw

counterclockwise

nut

(22).

IMPORTANT

Delete

Figure

AMENDMENT

Amend

Figure

the

governor

9-10.

HIGH

Walbro

carburetor

will

necessary,

adjustment

screw

(21)

admits

Restricting

9-8.

High-Altitude

TO

SECTION

Circuit

10-1.

governor

(Step

speed

ALTITUDE

be

necessary

see

screw

clockwise

(21)

until

clockwise

more

fuel,

the

Diagram

sensitivity

is

61

CARBURETOR

be

can

equipped

for

Figure

9-7

locking

until

the

engine

restricts

making

fuel

flowtothe

Carburetor

-

10

TROUBLESHOOTING

7)

(Step

adjusted,

with

proper

and

nut

the

operation

proceed

(22).

Apply

engine

operates

the

fuel

the

flow,

air-fuel

point

Adjustment

is

adjusted,

the

governor

MODIFICATION

an

adjustable

follows:

as

near-full

a

begins

smoothly;

making

mixture

where

the

governor

sensitivfty

main

at

a

particular

engine

falter

to

then

continue

air-fuel

the

richer.

the

mixture

(Step

(Optional)

for

jet

altitude.

loadtothe

lose

and

counterclockwise

mixture

Remove

is

too

EOWE3

AC

(Step

speed

MAY

71

(Figure

high-altitude

Whenever

welding

RPM.

Rotate

leaner.

the

engine

lean

,,_-_~___

load.

will-cause

5EU~A4~.

~

S~3ED

MUST

6)

need

readjustment.

9-7)

operation

carburetor

a

generator.

main

the

rotation

Rotating

Tighten

valve

GRCcu~UIC

be

readjusted.

(above

adjust

Rotate

adjustment

of

1/4

the

screw

the

locking

burning.

4000

the

turn.

(21)

*.OTE

33

72

r.._77

No.

REAR

B-081

127

24

VIEW

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23

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CAUTION

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AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-457C

Page

E

p.

6677

OF

CONTENTS

Page

No.

Section

TABLE

No.

SECTION

SECTION

SECTION

SECTION



1

SAFETY

1

-1.

Introduction

-

2.

General

1

-

1

Arc

3.

1-4.

2-1.

2-2.
2-3.

2-4.

3-1.
3-2.

-

3
3-4.
3-

4-1.

-

4

-

4

-

4

4-5.

Welding

Standards

2

INTRODUCTION

General

Receiving-Handling

Description

Safety

INSTALLATION

3

Location

Weld

Output

3.

Equipment

Remote

5.

120/240

4

ENGINE

Lubrication

2.

Coolant

3.

Preparing

Cleaner

Air

4.
Fuel

RULES

Precautions

Booklet

Connections

Grounding

Amperage

Volts

AC

PREPARATION

System

New

Battery

OPERATION

FOR

Index

Terminal

Control

Terminals..

For

Connections

Service

OF

ARC

WELDING

POWER

SOURCE

1

3

4

5

5

5

5

7

8

8
8
9
9

SECTION

SECTION

SECTION

5-1.

-

5
5-3.

5-4.

5-5.

-

5

5-7.

5-8.
5-9.

6-1.
6-2.
6-3.

6-4.

6-5.

6-6.

6-7.

-

6

7-

-

7

-

7

-

7

2.

6.

8.

1.

2.

3.

4.



FUNCTION

5

Volts

120

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Fine

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Remote

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Duty
Polarity

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240

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6

FUNCTION

Choke

Push

Start

Idle

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Engine

Temperature

Pressure

Oil

Electrical

Hour

Total



SEQUENCE

7

Sheilded

Power

Starting

Engine

AC

Amperage

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AC

Control

Button

Switch

Ammeter

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Metal-Arc

Plant

Operation

The

Down

Shut

OF

GENERATOR

Receptacle

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Control

Curves

Duplex

OF

ENGINE

And

Gauge

OF

OPERATION

(SMAW)

Engine

Receptacle

CONTROLS

Switch

Welding

CONTROLS

10

10
10

10

10

11

11
11
11

12
12
12
12
12

12

12
12

13
13

13
13

Section

SECTION

8-1.

-

8

8-

No.



8

General

Collector

2.

3.

Welding

GENERATOR

Cables

Ring

MAINTENANCE

Brushes

Page

No.

14

14
14

SECTION

SECTION

PARTS

9

9-1.

Lubrication

9~

2.

Coolant

9-3.

Governor

9.

4.

Carburetor

9-

5.

Vacuum

9.6.Idle
9-

7.

Carburetor

9-8.Air
9-

Idle

9.

9.10.

High

9.11.

Key

9-12.

Spark

10

LIST

ENGINE

MAINTENANCE

System

Service

Float

Circuit

Control

Cleaner

Control/Governor

Type

TROUBLESHOOTING

Altitude

Ignition

Arrestor

Time

Air

Temperature

Service

Carburetor

Setting

Filter

Air

Delay

Switch

Adjustment

Selector

Linkage

Modification

Lubrication

Adjustment

14

14

15

15

15

15
15
16

17

18
18

18

SECTION

1-SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

1-2.

A.

B.

INTRODUCTION

We

learn

experience,
wasteful,

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ing

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given.

technical

Read

to

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2

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Page

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paragraph

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or

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TIONS
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downstream

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gas.

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should

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clamps

substitute)

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leaks.

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for

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less

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right

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and

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connections.

smooth

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on

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to

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pressure

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staging-support

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before

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entry

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eyes

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precautions

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ultraviolet

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painful.

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clothing

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of

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sparks.

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from

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shield

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to

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equipment.

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line

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ment

the

to

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receptacle.

use

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precautions

engine

monoxide

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with

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cable

connections

strike

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brittle

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rupture

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hot

conductors

in

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shock

a

STAND,

welding,

against

and

body

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electrically

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installing,

power

the

building

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connection.

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single-phase

line.

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-

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a

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touching

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cord

for

connection

grounded

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connected

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rated
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arc

area

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ungrounded,

person

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clothing

insulation

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electrical

currents

the

connect

source,

currents

current

electrical

NOT

wire,

dangerous

check

switchbox.

a

grounded

broken

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exhaust

kill.

can

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capacity.

overheat

on

a

cylinder

that

later

under

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dry.

against

rubber

sea

HOT

to

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control,

ground.

safely.

may

conduit,

such

liquid

Check

If

equipment

connect

the

or

ground

bare

metal

a

ground

to

a

switchbox,

the

to

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off

in

1-2B.

be

must

in

may

can

in

or

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condition

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cables

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other

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electrically-HOT

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body

OR

ON,

suitable

protection.

Never

work

electrical

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moisture

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water,

-

or

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Conductors

shock,

only

lead

If

ground

through

frames

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Equipment

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oil

as

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phase

3-phase

to

the

equipment

equipment

for

continuity.

of

equipment

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provided

a

three-prong

receptacle,

prong

connect

ground

prong.

enabling

table,

to

only

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overload

fire.

cause

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pressure

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in

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shock.

between

metal-reduces

dangerous

the

body.

of

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water

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made

fatally.

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pipe

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requirement

power

two

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frames

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Stay

or

sweat

body

unit

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NOT

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ANY

of

equip

is

available,

wires

of

lead

electri-.

possibly

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sure

at

connec

the

equip

ground

is

added

ground

the

line

cord

mating

a

plug,

lead

can

DO

sur

on

can

and

the

lead

for

lead

air.

a

It

a

as

to

to

or

Trademark

of

Proctor

&

Gamble.

OM-457

Page

3

2.

Electrode

insulated

Fully

holders

use

3.

Connectors

insulated

Fully

welding

4.

Cables

Frequently

IMMEDIATELY

damaged

bared

cable.

resistance

cable

Keep

hot

metal

5.

Terminals

Terminals
have

insulating

6.

Electrode

Electrode

switch

of

trigger

gun

other

HOT

7.

Safety

devices

Safety

not

be

disconnected

Before

installation,

OFF

all

switches)

all

nect

volts

line-cord

Holders

with

cable

lengths.

inspect

insulation

Cables

equivalent

dry,

and

sparks.

And

and

covers

Wire

wire

metal-arc

gas

is

pressed.

parts.

Devices

such

power

to

prevent

cables

plu~.

electrode

protruding

lock-type

cables

REPLACE

to

with

to

free

of

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other

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secured

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es
or

inspection,

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accidental

from

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screws.

connectors

for

those

avoid

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original

oil

and

Exposed

parts

before

electrically

welding

equipment

hands

interlocks

shunted

or

line

turning

power

should

wear,

with

areas

cable.

grease,

Parts

of

and

and

out.

service,

fuses

be

used.

should

be

cracks

excessively

-

lethal

be

may

and

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electrical

operation.

HOT

when

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ON

clear

body

circuit

breakers

of

equipment,

lock

(or

ON

of

power.

and

source,

used

and

shock

taped

units

the

and

of

pull

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to

damage.

worn

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115

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connect

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power

1-4.

STANDARDS

For

or

their

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burns,

equipment

all

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ANSI

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Page

4