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Trailblazer
®
302 Air Pak
™
Quick
Specs
Issued Dec. 2011 • Index No. ED/4.78
Gas Engine-Driven Welder/
AC Generator/Air Compressor/
12/24 V Battery Charger/Jump Starter
Industrial Applications
Fabrication
Maintenance
Repair
Structural Steel Work
Sheet Metal
Processes (X-Ray Quality)
Stick (SMAW)
MIG (GMAW)
Flux-Cored (FCAW)
AC/DC TIG (GTAW)
Battery Charger/Jump Starter
Air Carbon Arc (CAC-A) Cutting and Gouging
Rated: 3/16-inch carbons,
Capable: 1/4-inch carbons
Air Plasma Cutting and Gouging with optional Spectrum ® models
Rated: 5/8-inch mild steel
Output Range
DC Stick 25– 300 A DC TIG 10 – 300 A
AC TIG/Stick 10 – 225 A MIG/FCAW 13 – 35 V, 350 A
Generator Power Output Rated at 104˚ F (40˚ C)
Peak: 13,000 W — Continuous: 11,000 W
Air Compressor
31 CFM, 100% Duty Cycle, 80 – 160 PSI
Battery Charger/Jump Starter
Battery Charger: 12/24 V, 10–75 A
Battery Jump Starter: 12/24 V, 450 A /350 A
The Power of Blue
®
.
The all-in-one tool that delivers multiprocess output for welding, plasma cutting, gouging, air tools, and
12/24-volt battery charger/jump starter.
Improved!
Trailblazer 302 Air Pak with Battery
Charger/Jump Starter (Welder, Generator,
Air Compressor, Battery Charger)
Welder/generator/air compressor/battery charger 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
Equipment Sales US and Canada
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
Website
MillerWelds.com
Trailblazer
®
302 Air Pak
™
Features
Size and Weight
Takes only half the bed space of a separate engine-driven air compressor and welder, freeing up to 50 percent more room on your truck for equipment and supplies. Plus decreases axle weight up to 25 percent.
Battery Charger/Jump Starter
• Provides selectable 12- or 24-volt battery charging capability
• Provides up to 450 amps of battery jump-starting capability
• Convenient front panel battery charger/jump starter access
• 25-foot battery jumper cables available (#300 422)
Independent Weld and Generator Advantages
• 13,000 watts of voltage-regulated power
• No interaction between grinders, power tools, etc. and the welding arc
• Generator power is independent of weld
• Four-pole weld generator produces the best arc quality
Weld Power
Industrial Rotary-Screw Air Compressor
• Runs most air impact wrenches at idle
• Produces 31 CFM of air at 100 percent duty cycle
• Delivers 80 –160 PSI of air with no storage tank
• Gives 100 percent deliverable air
• Compressor is warranted by Miller for three years
2
Generator Power
Trailblazer
®
302 Air Pak
™
Features
Easy to Service
Toolless top access to:
• Engine air cleaner
• Engine oil check/fill dipstick
• Battery
• Compressor oil check/fill dipstick
• Compressor oil separator
• Air compressor air filter
Toolless side access to:
• Engine oil filter
• Engine oil drain
• Engine fuel filter
Rear access to:
• Compressor oil filter
• Compressor oil drain
Front Panel Air
Pressure Adjustment
• Simple to adjust the correct air pressure for specific applications (80 –160 PSI)
• Lower pressure will increase engine power for more gouging and plasma cutting output capabilities
Easy Operation
Reduce fuel consumption and noise by using the front panel air flow control which matches engine speeds to air flow requirements for tools, plasma cutting and gouging.
3
4
Answers to Frequently Asked Trailblazer
®
302 Air Pak
™
Questions
Air facts
• Moisture going into a compressor also comes out.
• Air compressors heat air, turning moisture droplets into vapor.
How can I reduce moisture in the air?
Air Cooler with Separator #300 420
• Most popular.
• The cooler cools air which turns vapor moisture into droplets and the separator removes the droplets.
• Removes 70 percent of the moisture from the air.
• Use for most applications including tools, blasters, plasma cutters and gouging.
• Effective when temperatures are above freezing (this is also when the most moisture is in the air). Below 32 degrees
Fahrenheit (0° C) the separator can freeze. If this happens, bypass the cooler/separator system and continue air operations without drying it.
• Fully integrated inside of the Air Pak.
RTI Filter #300 491
• Recommended for plasma cutting. Separators remove droplets of water, not vapor, but this is good enough for most plasma cutting applications.
• Because compressors heat air, this filter option is less effective at removing moisture (heat turns droplets into vapor and vapor is not filtered).
Desiccant Air Dryer #300 690
• Cools air and removes 99 percent of the moisture from the air.
• Primary use is when temperature ranges below freezing and moisture still must be removed from the air.
• Has a built in heater.
• Mounted externally from the machine with some wiring that needs to take place inside of the machine.
Note: Reduces air flow up to four CFM at all speeds.
What does Average vs Continuous CFM mean?
• Air tools are often rated as “Average CFM.” “Average CFM” is typically based on 15-second usage intervals.
Impact wrenches, button punch/deck tools, and decking crimp tools are typically used intermittently (short time durations).
• Continuous CFM: This rating is based on continuous usage.
Air grinders and sand blasters are examples of air tools that are used continuously.
The Air Pak will easily run the following:
Air Tools
3/4-inch Impact Wrench (IR 2141)
3/4-inch Impact Wrench (Speedaire)
1/2-inch Impact Wrench (IR 231C)
Needle Scaler (IR 182LNA1)
4-1/2-inch Grinder (Dayton)
1/4-inch Die Grinder (IR G1H350RG4) 6
1/2-inch Drill (IR 7AQSTB) 4
Air Shears (IR 7802SA)
Sand Blaster
4
—
Soda Blaster
Button Punch/Deck Tool
Decking Crimp Tool
—
—
4
4
3
7
Average
CFM*
10
7
*1/2-inch air hose is recommended for better tool efficiency.
Note: Impact wrenches use Continuous CFM when “free” spinning.
In actual use, CFM requirements are less. Thus, the Trailblazer Air Pak is rated to run a 40 CFM impact wrench.
25
17
21
6
18
4
15
22
13
26
Continuous
CFM*
40
26
How do I access the air?
The Trailblazer Air Pak provides four convenient air compressor access points. The air outlet connection requires a 1/2-inch
NPT swivel fitting.
MAX FLOW ABSOLUTE HUMIDITY
10
5
0
0 150 50 100
DRYER AIR PRESSURE (PSI)
Air Cooler with Separator (#300 420)
Desiccant Air Dryer (#300 690)
No Air Cooler or Dryer
Specifications
(Subject to change without notice.)
Welding
Mode
CV/DC
CC/DC
CC/AC
Process
MIG/FCAW
Amp/Volt Ranges
13–35 V
Stick/TIG
Stick/TIG
Air
Compressor
10–300 A
10–225 A
31 CFM at 3600 RPM
28 CFM at 3000 RPM
22 CFM at 2400 RPM
Battery Charger/
Jump Starter
12 V
24 V
Weld Output Rated at 104° F/40° C*
300 A, 32 V at 100% Duty Cycle
350 A, 32 V at 60% Duty Cycle
280 A, 32 V at 100% Duty Cycle
200 A, 25 V at 60% Duty Cycle
31 CFM at 100% Duty Cycle
Single-Phase
Generator Power
Peak:
13,000 watts
Continuous:
11,000 watts
120/240 VAC,
100/50 A, 60 Hz
450 A, 12 V, Jump Start
350 A, 24 V, Jump Start
10 – 75 A, Charge
Sound Levels at
Rated Output
7 m (23 ft.) Dimensions
2400 RPM (Idle)
73.4 dB (98.4 Lwa)
3000 RPM
76.5 dB (101.5 Lwa)
3600 RPM
81.2 dB (106.6 Lwa)
H: 28 in. (838 mm)
H: 34.5 in. (876 mm)
(to top of exhaust)
W: 20 in. (508 mm)
D: 59.625 in. (1514 mm)
Weight
Without
Fuel:
771 lb.
(350 kg)
*Rated at sea level. Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Engine Specifications (Engines warranted separately by the engine manufacturer.)
Engine Brand/
Warranty
Kohler: 3-year mfg
Horsepower (HP)
30 HP at 3600 RPM
Type
Twin-cylinder, four-cycle overhead valve
Weld Speed
3600/3000 RPM
Idle
Speed
2400 RPM
Fuel
Capacity
12 gal. (45 L)
Oil Capacity
1.75 qt. (1.7 L)
Standard
Shutdowns
Low Oil Pressure
Air Compressor Specifications
Compressor
Warranty
3-year True Blue ®
Warranty by Miller
Features
Rotary screw with electric clutch for on/off. Oil change intervals 500 hours.
Free Air
Delivery at
2400 RPM (Idle)
22 CFM
(0.62 m 3 /min.)
Free Air
Delivery at
3000 RPM
28 CFM
(0.79 m 3 /min.)
Free Air
Delivery at
3600 RPM
31 CFM
(0.88 m 3 /min.)
Working
Pressure
Constant
80 –160 PSIG
Duty
Cycle
100%
Oil
Capacity
1.75 qt.
(1.7 L)
Automatic
Compressor
Shutdowns
High Pressure
(160 PSI)
Performance Data
AIR COMPRESSOR FUEL CONSUMPTION
(at 100% Duty Cycle)
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
2400 3000 3600
ENGINE SPEED RPM
Mounting Specifications
A. 20 in. (508 mm)
B. 16.5 in. (419 mm)
C. 1.75 in. (44 mm)
D. 6.062 in. (154 mm)
E. 32.75 in. (832 mm)
F. 59.625 in. (1514 mm)
G. .406 in. (10 mm) diameter
WELD/GENERATOR FUEL CONSUMPTION
2.25
2.00
1.75
1.50
1.25
1.00
0.75
IDLE
0.50
0.25
0.00
0 50 100 150 200 250 300 350
DC WELD AMPS AT 100% DUTY CYCLE
400
0 2 4 6 8 10
GENERATOR POWER IN KILOWATTS AT
100% DUTY CYCLE
12
FUEL CONSUMPTION DATA
• 12-gallon fuel capacity.
• On a typical job using 1/8-inch 7018 electrodes (125 A, 20% duty cycle) expect over 16 hours of operation.
• Welding at 150 A, 40% duty cycle uses approximately: 3/4-gallon per hour — over 13 hours of operation.
• Many air tools can be used when running at idle. Running at idle with a compressor load will provide 14 hours of run time.
• Running the air compressor at 31 CFM will provide 11 hours of run time.
• Reduce fuel consumption by turning the air compressor off when the Air Pak is not in use.
For weld/generator fuel consumption chart see chart at left.
Height: 28 in. (838 mm)
34.5 in. (876 mm)
(to top of exhaust)
Width: 20 in. (508 mm)
Depth: 59.625 in. (1514 mm)
Lifting eye rating:
1000 lb. (453 kg)
A B
C
D
G 4 Holes
E
F
5
Function and Benefit Guide
1
5
6
2
3
4
7
11
12
13
14
8
9
10
*Category Exclusive
1. Self-calibrating digital weld meters with
meter maintenance displays capable of displaying engine and air compressor oil change intervals.
2. Four preset DIG settings* offer the best arc characteristics for different electrodes and joint designs. The amount of DIG determines how much amperage (heat) varies with Stick arc length. The combined
Process switch along with preset DIG settings make the Trailblazer easy to set without the complication of multiple switches.
3. Adaptive Hot Start ™ * (Stick) automatically sets starting amperage for great arc starts.
4. Great MIG/FCAW performance and arc
starts make the Trailblazer’s arc best in its class. Easy to run all wires from .023-inch solid wires to large diameter 5/64-inch flux-cored wires.
5. Lift-Arc ™ TIG with Auto-Crater ™ * and
Auto-Stop ™ *
6. Air compressor, battery charger/jump starter, and maintenance selector
7. Air pressure gauge/regulator gives the approximate air pressure settings needed for common air tools/plasma/carbon arc gouging. The pressure gauge also reads the actual air pressure being used. The regulator allows user control of the pressure settings up to 160 PSI.
8. Front panel fuel gauge* LEDs indicate fuel level. The “E” LED lights when fuel is low.
9. AC/DC and battery charger/jump starter
switch allows selection between AC or
DC weld output and battery charger/ jump function.
10. Battery charger/jump starter receptacle for connection to battery charger/jump cable (12 or 24 volt).
11. Standard 14-pin receptacle for simple connection of remote controls and wire feeders. It features Auto Remote Sense ™ * which automatically switches from Panel to
Remote Amperage/Voltage (A/V) control with remote connected. Eliminates confusion of the Panel/Remote A/V switch.
12. Speed control switch allows for control of engine speed based on the switch position.
In the auto speed mode, the speed will be auto selected depending on total power needed. The speed will auto select between
3000 and 3600 RPM depending on weld demand or weld plus air demand. Anytime auxiliary load is needed the engine will go to
3600 RPM.
13. Engine choke control
14. 120 VAC and 240 VAC receptacles with circuit breakers
Note: For matching plug, order #119 172.
6
Genuine Miller
®
Accessories
*Available as factory option. See ordering information on back page.
Protective Cover
#300 379
Heavy-duty, waterresistant and mildewresistant covers protect and maintain the finish of the welder.
For models without Protective Cage.
Protective Cage with Cable Holders
#300 473
Rugged cage with cable holders protects your investment. Can be used with trailer.
25-foot Battery
Charger/Jump Cable
#300 422
GFCI Protection* #195 496 Field
Kit contains two GFCI 120 VAC duplex receptacles. (240 VAC GFCI receptacle not required).
Electric Fuel Pump* #195 214 Field
Improves engine starting and high-output performance at high altitude.
Remote Oil Drain and Filter Kit —
Front/Chassis Truck Mounted
#300 236 Field. For Kohler.
Engine Tune-Up Kit #238 743 Field
Kohler CH750 tune-up kit includes spark plugs and engine filters.
Air Compressor Tune-Up Kit
#235 202 Field
Tune-up kit includes oil filter, air filter and oil separator.
Air Cooler with
Separator*
#300 420
Cools and removes moisture from the air supply.
Designed for use
above 32 degrees
Fahrenheit (0° C).
Bypass in colder temperatures. See air dryer choices on page 4 for details.
Micron Filter Element #203 877
Replacement micron filter for the Air Cooler with Separator.
RTI Filter and Bracket
#300 491
Dryer will remove water, dirt and oil as small as one micron with 99.9 percent efficiency. Can be mounted on plasma cutter or on wall. Install as close as possible to point of air consumption. Designed for use above 32 degrees Fahrenheit (0° C).
Bypass in colder temperatures. See air dryer choices on page 4 for details.
Desiccant Air Dryer System
#300 690
A regenerating inline air dryer system that eliminates moisture in the air stream to prevent air tool freeze-ups in cold climates.
See air dryer choices on page 4 for details.
Female
Receptacle
Adapter Cord, Full KVA #300 517 Field
NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to common
Millermatic ® and Spectrum ® 240 V plug.
MIG/Flux-Cored Welding
SuitCase ® X-TREME ™
8VS Wire Feeder
#951 182
SuitCase ® X-TREME ™
12VS Wire Feeder
#951 184
Lightweight, voltage-sensing wire feeders include secondary contactor, gas valve and drive roll kit. See Lit. Index No. M/6.41.
SuitCase ® 8RC
Wire Feeder
#951 186
SuitCase ® 12RC
Wire Feeder
#951 188
Lightweight and flexible enough to run a variety of wires up to .062-inch diameter.
Includes remote voltage control and drive roll kit. See Lit. Index No. M/6.5.
Spoolmatic ® 30A
Spool Gun #130 831
Air-cooled, 200-amp,
1-pound spool gun for aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
Millermatic ® 180 Auto-Set ™ #907 312
See Lit. Index No. DC/12.44
Millermatic ® 212 Auto-Set ™ #907 405
See Lit. Index No. DC/12.46
Plasma Cutting
Spectrum 375 X-TREME and 625 X-TREME shown.
Spectrum ® 375 X-TREME ™
See Lit. Index No. PC/9.2.
Spectrum ® 625 X-TREME ™
See Lit. Index No. PC/9.6.
#907 529
#907 531
Spectrum ® 875 #907 390-01-1
See Lit. Index No. PC/9.8.
The Spectrum 375 X-TREME and 625
X-TREME come complete with protective
X-CASE ™ (not shown).
TIG (GTAW) Welding
Dynasty ® 200 Series
For premium portable AC/DC
TIG arc quality. See Lit. Index
No. AD/4.8.
HF-251 Series #042 388
HF-251D-1, 115 VAC
High-frequency arc starter and stabilizer. See Accessory
Lit. Index No. AY/5.0.
Remote Controls
RHC-14 Hand Control
#242 211 020
20-foot (6 m) cord
#242 211 100
100-foot (30.5 m) cord
Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x
3.25 inches (102 x 102 x 82 mm). Includes cord and 14-pin plug.
7
Trailers and Hitches
(Note: Trailers are shipped unassembled.)
HWY-224 Trailer #043 805 For highway use.
A 2650-pound (1202 kg) capacity trailer.
Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension.
Includes jack stand, 2-inch (50 mm) ball hitch, fenders and lights.
Note: Trailer is shipped unassembled.
Cable Tree #043 826
Provides an area to conveniently wrap weld cables and extension cords.
Dual Hitch #300 831
2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly.
Trailer Specifications (Subject to change without notice.)
Model
HWY-224
Gross Axle
Weight Rating
3500 lb.
(1588 kg)
* Width at outside of fenders.
Gross Vehicle
Weight Rating
2960 lb.
(1343 kg)
Net
Payload
2650 lb.
(1202 kg)
Height of Bed
18.5 in.
(470 mm)
Road
Clearance
7.5 in.
(191 mm)
Track (Center to center of tires)
52 in.
(1321 mm)
Standard Tires
(Standard rating or P-size rating)
B78-13
Dimensions
Length: 105 in. (2667 mm)
Width: 59.5 in. (1511 mm)*
Net
Weight
320 lb.
(145 kg)
Ordering Information
Equipment and Options
Trailblazer ® 302 Air Pak ™ with Battery Charger/Jump Starter
GFCI Protection
Electric Fuel Pump
Remote Oil Drain and Filter Kit
Engine Tune-Up Kit
Air Compressor Tune-Up Kit
Adapter Cord, Full KVA
Full KVA Plug
Accessories
Protective Cover
Protective Cage with Cable Holders
25-foot Battery Charger/Jump Cable
Air Cooler with Separator
Micron Filter Element
RTI Filter and Bracket
Desiccant Air Dryer System
SuitCase ® Portable Wire Feeders
Spoolmatic ® 30A Spool Gun
WC-24 Control
Millermatic ® Series MIG Welders
Spectrum ® Plasma Cutters
Dynasty ® 200 Series
HF-251D-1
RHC-14 Hand Control
HWY-224 Trailer
Cable Tree
Dual Hitch
Stock No.
#907 549
#907 549-001
#907 549-002
#907 549-003
#195 496
#195 214
#300 236
#238 743
#235 202
#300 517
#119 172
#300 379
#300 473
#300 422
#300 420
#203 877
#300 491
#300 690
#130 831
#137 549
#042 388
#242 211 020
#242 211 100
#043 805
#043 826
#300 831
Date:
Description
Kohler, with GFCI Receptacles and Electric Fuel Pump
Kohler
Kohler, with Cooler/Separator
Kohler, with Cooler/Separator, GFCI Receptacles and Electric Fuel Pump
Field
Field. Improves starting and performance at high altitude
Field
Field. For Kohler CH750 (Gas). Order from Miller Service Parts
Field. For screw compressor. Order from Miller Service Parts
Field
Field
Blue with logo
See page 4 for more information
For use with Air Cooler with Separator
See page 4 for more information
Reduces air flow up to four CFM at all speeds. See page 4 for more information
See page 7
Requires WC-24 Control. See Lit. Index No. M/1.73
See Lit. Index No. M/1.5
See page 7
See page 7
See Lit. Index No. AD/4.8
115 VAC. See Lit. Index No. AY/5.0
20-ft. (6 m) cord
100-ft. (30.5 m) cord
Combination 2-in. (50 mm) ball hitch and 3-in. (76 mm) lunette eye
Total Quoted Price:
Qty. Price
Distributed by:
Litho in USA
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