Trailblazer 280 NT

TM-4402B October 2001
Eff. w/Serial Number LA095390

Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging

with SpectrumR Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
Trailblazer 280 NT
Visit our website at

www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARNING
3-3. Fuel Consumption While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-4. Fuel Consumption While Using Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This product, when used
3-5. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 for welding or cutting,
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 produces fumes or
gases which contain
3-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 chemicals known to the
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 State of California to
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 cause birth defects and,
4-2. Engine Prestart Checks (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 in some cases, cancer.
4-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 (California Health &
Safety Code Section
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25249.5 et seq.)
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WARNING
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-9. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Battery posts, terminals
4-10. Adjusting MIG Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 and related accessories
contain lead and lead
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 compounds, chemicals
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 known to the State of
5-2. Remote Amperage/Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 California to cause cancer
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 and birth defects or other
6-1. Auxiliary Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 reproductive harm. Wash
6-2. Optional Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 hands after handling.
6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 7 – MAINTENANCE (ONAN-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CALIFORNIA
7-1. Routine Maintenance (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Proposition 65
7-2. Maintenance Label (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Warning
7-3. Servicing Air Cleaner (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diesel engine exhaust and
7-4. Servicing Optional Spark Arrestor (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
some of its constituents
7-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Onan-Powered Units) . . . . . . . . . . . . . . . . . 21 are known to the State of
7-6. Adjusting Engine Speed (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 California to cause
7-7. Overload Protection (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 cancer, birth defects, and
SECTION 8 – MAINTENANCE (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 other reproductive harm.
8-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-3. Servicing Air Cleaner (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-4. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . 27
8-6. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-7. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 9 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 10 – EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 11 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 11-3) . . . . . . . . 40
11-3. Troubleshooting Values And Readings For Circuit Diagram (Use With Section 11-2) . . . . . . 42
11-4. Waveforms For Section 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11-5. Idle Module PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11-6. Idle Module PC1 Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11-7. Field Current Control Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11-8. Field Current Control Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11-9. Capacitor Board PC4 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11-10. Capacitor Board PC4 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11-11. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11-12. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 12 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 13 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION 14 – PARTS LIST FOR LA095390 Thru LA289766 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION 15 – PARTS LIST FOR LA289767 THRU LB104520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SECTION 16 – PARTS LIST FOR LB104521 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_rtm 7/99 / OM-4402J
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see STATIC (ESD) can damage PC boards.
the symbol, watch out, and follow the related instructions to
D Put on grounded wrist strap BEFORE handling
avoid the hazard.
boards or parts.
Y Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.

ENGINE EXHAUST GASES can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un- D Do not breathe exhaust fumes.
less the procedure specifically requires an en- D Use in open, well-ventilated areas, or vent ex-
ergized unit. haust outside and away from any building air in-
D Insulate yourself from ground by standing or working on dry insu- takes.
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping D Stop engine and let it cool off before checking or
engine on inverters. adding fuel.
D Stop engine on inverter and discharge input capacitors according D Do not add fuel while smoking or if unit is near
to instructions in Maintenance Section before touching any parts. any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.

D Keep away from moving parts such as
fans, belts, and rotors.
BATTERY EXPLOSION can BLIND.
D Have only qualified people remove
guards or covers for maintenance and D Always wear a face shield, rubber gloves, and
troubleshooting as necessary. protective clothing when working on a battery.
D Keep hands, hair, loose clothing, and tools away from mov- D Stop engine before disconnecting or connect-
ing parts. ing battery cables.
D Before working on generator, remove spark plugs or injec- D Do not allow tools to cause sparks when working on a battery.
tors to keep engine from kicking back or starting. D Do not use welder to charge batteries or jump start vehicles.
D Block flywheel so that it will not turn while working on gener- D Observe correct polarity (+ and –) on batteries.
ator components.
D Disconnect negative (–) cable first and connect it last.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face
D Do not tip battery.
shield during servicing.
D Replace damaged battery.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing. D Flush eyes and skin immediately with water.
Trailblazer 280 NT TM-4402 Page 1

STEAM AND HOT COOLANT can burn. TILTING OR TIPPING can cause injury.
D If possible, check coolant level when engine is D Do not put any body part under unit while lifting.
cold to avoid scalding. D Always use proper equipment (hoists, slings,
D Always check coolant level at overflow tank, if chains, blocks, etc.) of adequate capacity to lift
present on unit, instead of radiator. and support components (stator, rotor, engine,
etc.) as needed during job.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two PINCH POINTS can injure.
statements. D Be careful when working on stator and rotor assemblies.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap. H.F. RADIATION can cause interference.
MAGNETIC FIELDS can affect pacemakers. D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Pacemaker wearers keep away from servicing communications equipment.
areas until consulting your doctor. D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
FALLING UNIT can cause injury. D If notified by the FCC about interference, stop using the equip-
ment at once.
D Use equipment of adequate capacity to lift and
support unit and components. D Have the installation regularly checked and maintained.
D Use lifting eye to lift unit only, NOT running D Keep high-frequency source doors and panels tightly shut, keep
gear, gas cylinders, or any other accessories. spark gaps at correct setting, and use grounding and shielding to
D Securely attach components to lifting equip- minimize the possibility of interference.
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
HOT PARTS can cause severe burns.
D Reduce current or reduce duty cycle before
D Allow cooling period before servicing. starting to weld again.
D Wear protective gloves and clothing when D Do not block or filter airflow to unit.
working on a hot engine.
D Do not touch hot engine parts bare-handed.
READ INSTRUCTIONS.
SHOCK HAZARD from testing. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Stop engine before making or changing meter
lead connections. D Consult the Owner’s Manual for welding safety
precautions.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip. D Use only genuine replacement parts.
D Read instructions for test equipment. D Reinstall injectors and bleed air from fuel system according to
engine manual.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from
committee’s judgment, has not demonstrated that exposure to power- operator as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-4402 Page 2 Trailblazer 280 NT

SECTION 2 – DEFINITIONS
2-1. Symbol Definitions
Fast Fast/Slow
Stop Engine Slow (Idle)
(Run, Weld/Power) (Run/Idle)
Start Engine Panel/Local Temperature Fuel
Check Valve
Engine Oil On Battery (Engine)
Clearance
Engine
Read Operator’s
Manual A Amperes
V Volts
MIG (GMAW),
Stick (SMAW) TIG (GTAW) Circuit Breaker
Wire
Alternating Current
Positive Negative Output
(AC)
Protective Earth
Time
h
Hours
s Seconds
(Ground)
Do not switch while Remote 14

14 Work Connection Engine Choke
welding Receptacle
Electrode
Wire Feed Electrode Negative
Positive
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Rated Maximum Amperage Voltage
Welding Auxiliary Fuel
Welding Open-Circuit Range In Range In Engine
Mode Power Rating Capacity
Output Voltage CC Mode CV Mode
280 A, 25 V, Onan P220
100% Duty Air-Cooled,
20 – 280 A
Cycle Two-Cylinder,
(Onan)
CC/DC (Onan & Kohler) 80 Four-Cycle,
20 – 300 A Continuous: 8 kVA/kW, 20 HP Gasoline
300 A, 25 V, 66.6/33.3 A,
(Kohler) Engine
40% Duty Cycle 120/240 V AC, 60 Hz, 10 gal (38 L)
(Kohler) 10 – 33 V Single-Phase, or
Tank
280 A, 25 V, Peak: 9 kVA/kW Kohler CH-20
CV/DC 100% Duty 50 –– (w/Weld Contactor Off) Air-Cooled,
Cycle Two-Cylinder,
Four-Cycle,
200 A, 25 V, 20 HP Gasoline
CC/AC 75 40 – 200 A
60% Duty Cycle Engine

3-2. Dimensions, Weights, and Operating Angles
Dimensions
A
Height 33 in (838 mm) B
C
Width 18-3/4 in (476 mm)
Y Do not exceed tilt angles or engine could
Depth 45-1/2 in (1156 mm) be damaged or unit could tip.
D
A 18 in (457 mm) Y Do not move or operate unit where it could
G
tip.
4 Holes
B 16-1/2 in (419 mm)
C 3/4 in (19 mm) E

F
D 3-1/8 in (79 mm)
25°
E 32-3/4 in (832 mm)
F 45-1/2 in (1156 mm) 25° 25°
25°
G 13/32 in (10 mm) Dia.
Weight
Onan: 591 lb (268 kg)

Kohler: 567 lb (257 kg) Engine End 800 426
3-3. Fuel Consumption While Welding

US GAL/HR.
LITERS/HR.
7.57 2.00
6.62 1.75
5.68 1.50
DC WELD – ONAN
4.73 1.25
DC WELD – KOHLER
3.79 1.00
2.84 0.75
1.89 0.50
IDLE – ONAN
IDLE – KOHLER
0.95 0.25
0.00 0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE
201 526

3-4. Fuel Consumption While Using Auxiliary Power
US GAL/HR.
LITERS/HR.
7.57 2.00
6.62 1.75
5.68 1.50
4.73 1.25
AUX POWER – ONAN
3.79 1.00
AUX POWER – KOHLER
2.84 0.75
1.89 0.50
IDLE – ONAN
IDLE – KOHLER
0.95 0.25
0.00 0.00
0 1 2 3 4 5 6 7 8
OUTPUT AT 100% DUTY CYCLE (KW)
201 527
3-5. Auxiliary Power Curve

The ac auxiliary power curve
shows the auxiliary power available
in amperes at the receptacles.
280 140
240 120
200 100
AC POWER VOLTS
160 80
120 60
80 40
40 20
0 0
0 20 40 60 80 100 120 140 160
AC POWER AMPERES AT 120V
0 10 20 30 40 50 60 70 80
AC POWER AMPERES AT 240V
189 268

3-6. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
A. CC/DC Mode and amperage output capabilities of
the welding generator. Curves of
80 other settings fall between the
curves shown.
70
60
50
DC VOLTS
MAX
40
30
MIN
20
10
0
0 50 100 150 200 250 300 350 400
DC AMPERES
B. CV/DC Mode
50
40
Max
DC VOLTS
30
50%
20
10 Min
0
0 100 200 300 400 500 600
DC AMPERES
C. CC/AC Mode
80
70
60
50
AC VOLTS
40 MAX
30 MIN
20
10
0
0 50 100 150 200 250 300 350
AC AMPERES
189 280 / 189 282-A / 189 265

3-7. Duty Cycle
100% Duty Cycle at 280 Amperes DC Duty cycle is the percentage of 10

minutes that unit can weld at rated
load without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
350
DC WELD – KOHLER
300
WELDING AMPERES
DC WELD – ONAN
250
200
AC WELD
150
100
0 10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
199 467-A
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Bolt
unit down using holes pro-
Movement Airflow Clearance vided in base.
18 in Y Always securely fasten

Y Do not lift unit from end. (460 mm) welding generator onto
transport vehicle or trailer
18 in
and comply with all DOT and
18 in (460 mm)
other applicable codes.
(460 mm)
Y Always ground generator
OR frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
18 in 18 in 1 Generator Base
(460 mm) (460 mm) 2 Metal Vehicle Frame
3 Equipment Grounding
Terminal
Location Grounding 4 Grounding Cable
1 3
4 Use #10 AWG or larger insulated
GND/PE copper wire.
Y If unit does not have GFCI re-
ceptacles, use GFCI-
OR protected extension cord.
OR
Electrically bond genera-

tor frame to vehicle frame
2 by metal-to-metal contact. 2
install1 10/00 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854

4-2. Engine Prestart Checks (Onan-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
. Follow run-in procedure in engine

manual.
. This unit has a low oil pressure shut-

down switch. However, some condi-
tions may cause engine damage be-
fore the engine shuts down. Check
oil level often and do not use the oil
pressure shutdown system to moni-
tor oil level.
Fuel
Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in.
(13 mm) from top to allow room for ex-
pansion. Check fuel level on a cold en-
gine before use each day.
Oil
After fueling, check oil with unit on level
surface. If oil is not up to full mark on dip-
stick, add oil (see maintenance label).
. To improve cold weather starting:
Keep battery in good condition.
Full Store battery in warm area off con-
crete surface.
Use correct grade oil for cold

weather.
1/2 in
(13 mm)
Full
Gasoline
Ref. 151 983 / 801 942-C / Ref. 800 395

4-3. Engine Prestart Checks (Kohler-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
. Follow run-in procedure in engine

manual.
. This unit has a low oil pressure

shutdown switch. However, some
conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Fill fuel tank up to 1/2
in. (13 mm) from top to allow room for
expansion. Check fuel level on a cold
engine before use each day.
Oil
After fueling, check oil with unit on level
surface. If oil is not up to full mark on
dipstick, add oil (see maintenance la-
bel).
. To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area off con-
crete surface.
Full Use correct grade oil for cold

weather.
1/2 in
(13 mm)
Full
Gasoline
801 221 / 802 692

4-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection – Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 bottom of well (maximum).
Y Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6 Battery Charger
Y Read and follow all instruc-
2 tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
. When electrolyte is low, add

only distilled water to cells to
maintain proper level.
5 A For 30 Minutes Tools Needed:
OR
+
– rubbergloves
30 A For 12 Minutes
glasses
drybatt1 1/98 – S-0886

4-5. Connecting The Battery
Y Connect negative (–)

cable last.
+ –
Tools Needed:
3/8, 1/2 in Ref. 800 394-C / Ref. 203 073 / Ref. S-0756-D
4-6. Installing Exhaust Pipe

Y Engine backfire can cause se-
vere burns or other injuries.
Do not point exhaust pipe to-
ward control panel. Keep
away from exhaust outlet.
. Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in 801 681 / Ref. 203 073
4-7. Connecting To Weld Output Terminals

Y Do not connect to CC and CV
terminals at the same time.
1 Work Weld Output Terminal
2 Stick/TIG (CC) Weld Output
Terminal
3 Wire (CV) Weld Output
Terminal
For MIG welding, connect work
cable to Work terminal and wire
feeder cable to Wire (CV) terminal.
For Stick/TIG welding, connect
work cable to Work terminal and
electrode holder cable to Stick/TIG
(CC) terminal.
1 2 3
801 943-B / Ref. 203 073

4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Stop engine before 10 – 60% 60 – 100%
connecting to weld out- Welding
Duty Duty 10 – 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
* Thischart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E–
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
4-9. Remote 14 Receptacle Information
NOTE Engine runs at weld/power speed whenever a device connected to the remote 14
receptacle is running.
Socket* Socket Information
A 24 volts ac.
24 VOLTS AC
B Contact closure to A completes 24 volt ac contac-
A J tor control circuit. Protected by circuit breaker
K I CB5.
B
C L N H
I 115 volts ac.
D M G 115 VOLTS AC
E F J Contact closure to I completes 115 volt ac contac-
tor control circuit. Protected by circuit breaker
CB6.
C 0 to +10 volts dc output to remote control.

A/V D Remote control circuit common.
AMPERAGE
VOLTAGE E 0 to +10 volts dc input command signal from
remote control.
G Circuit common for 24 and 115 volt ac circuits.

GND
801 943-B K Chassis common.
*The remaining sockets are not used.

4-10. Adjusting MIG Weld Puddle Consistency
Y Stop engine.
Stabilizer DC-Z is factory
connected to suit most MIG (Wire
Welding) applications.
To change MIG weld puddle consis-
tency, proceed as follows:
Remove lower front panel and side
panel.
Starting from center of DC-Z, the
three leads 79 will be referred to as
inner, middle, and outer.
1 Stabilizer DC-Z
2 Inner Lead 79
3 Middle Lead 79
4 Outer Lead 79
5 Wire (CV) Weld Output
Terminal
Middle lead 79 is connected to Wire
(CV) weld terminal at the factory.
Disconnect middle lead 79 from
terminal.
To wet out weld puddle:
Remove insulation sleeve from in-
ner lead 79. Connect inner lead 79
to Wire (CV) terminal, reusing
hardware.
To stiffen weld puddle:
Remove insulation sleeve from out-
er lead 79. Connect outer lead 79 to
Wire (CV) terminal, reusing
hardware.
Slide sleeves over unused leads 79,
and secure with cable ties. Reinstall
panels.
3
End View
Tools Needed:
3/8, 7/16 in
801 944-C / Ref. 203 073

SECTION 5 – OPERATING WELDING GENERATOR
5-1. Front Panel Controls
1 2 3 4 5 6
8 7
Ref. 203 073
1 DC Polarity/AC Switch runs at idle speed at no load, and weld/power To Stop: turn Engine Control switch to Off
speed under load. In Run position, engine position.
Y Do not switch under load.
runs at weld/power speed.
Use switch to select AC weld output or polar- 6 Engine Hour Meter
ity of DC weld output. . Place switch in Run position to operate 7 Output (Contactor) Switch
most GMAW equipment.
2 Process Select Switch Use switch to control remote contactor if
5 Engine Choke Control
Use switch to select output for weld process. connected to remote 14 receptacle RC1
Use control to change engine air-fuel mix. (see Section 5-2).
3 A/V Control
To Start: pull out choke and turn Engine
Use control to select weld voltage or Y Weld output terminals are energized
Control switch to Start position. Release
amperage. Control may be adjusted while when Output (Contactor) switch is
switch and slowly push choke in when
welding. On and engine is running.
engine starts.
4 Engine Control Switch . If the engine does not start, let the
8 Remote Amperage/Voltage Switch
Use switch to start engine, select speed, and engine come to a complete stop before Use switch to select front panel or remote
stop engine. In Run/Idle position, engine attempting restart. amperage/voltage control (see Section 5-2).

5-2. Remote Amperage/Voltage Control
1 Remote 14 Receptacle RC1
Connect optional remote control to
RC1 (see Section 4-9).
2 Remote Hand Control
(Optional)
3 Remote Foot Control
(Optional)
. Engine runs at weld/power
speed whenever a device con-
1 nected to the remote 14 recep-
tacle is running.
In Example:
Process = Stick (SMAW)
Min = 40 A CC/DC
Max = 180 A CC/DC
Max (180 A DC)
Min (40 A DC)
Set Remote Set Polarity Switch Set Process and Adjust Remote Control
Control Switches A/V Control (Stick Welding Only)
801 943-B / 203 073 / S-0769 / S-0774

SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. Auxiliary Power Receptacles And Circuit Breakers
protected extension cord.
. Auxiliary power decreases as

5 6 weld current increases.
1 240 V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maxi-
mum output is 8 kVA/kW.
2 120 V 20 A AC Duplex
Receptacle RC2
1
3 120 V 20 A AC Duplex
Receptacle RC3
RC2 and RC3 supply 60 Hz single-
phase power at weld/power speed.
Maximum output from RC2 or RC3 is
2.4 kVA/kW.
4 Circuit Breaker CB1
CB1 protects all the receptacles from
4 overload. If CB1 opens, the recep-
tacles do not work.
3
. Place switch in On position to re-
set circuit breaker.
2 6 Circuit Breaker CB4
CB3 protects RC2 and CB4 protects
RC3 from overload. If a circuit break-
er opens, the receptacle does not
work.
. Press button to reset circuit

breaker.
Combined output of all receptacles
limited to 8 kVA/kW rating of the gen-
erator.
EXAMPLE: If 20 A is drawn from
Simultaneous Welding And Auxiliary Power Output each 120 V duplex receptacle, only
13 A is available at the 240 V
receptacle:
Total 120 V 240 V
Weld Current Power In 2 x (120 V x 20 A) + (240 V x 13 A) =
Receptacle Receptacle
In Amperes Watts 8 kVA/kW
Amperes Amperes
300 1600 14 7
250 3500 31 15
200 5140 46 23
150 6700 60 30
100 8000 66 33
0 8000 66 33
Ref. 203 073

6-2. Optional Auxiliary Power Receptacles
protected extension cord.
1 . Auxiliary power decreases as

weld current increases.
Combined output of all receptacles
limited to 8 kVA/kW rating of the
generator.
GFCI Receptacle Option
1 120 V 15 A AC GFCI Recep-
tacles GFCI2 and GFCI3
GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/kW. Cir-
cuit breaker protection is the same
as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
Simultaneous Welding And Auxiliary Power Output
button to reset receptacle and
resume operation.
Weld Current
Total 120 V 240 V . At least once a month, run
Power In Receptacle Receptacle engine at weld/power speed
In Amperes Watts Amperes Amperes and press Test button to verify
GFCI is working properly.
300 1600 14 7
250 3500 31 15
200 5140 46 23
150 6700 60 30
100 8000 66 33
0 8000 66 33
Ref. 203 073
6-3. Wiring Optional 240 Volt Plug

1 The plug can be wired for a 240 V,
3
2-wire load or a 120/240V, 3-wire
4 load. See circuit diagram.
1 Plug Wired for 120/240 V,
7 3-Wire Load
Current Available in Amperes
When wired for 120 V loads, each
240 V Each 120 V Duplex duplex receptacle shares a load
Receptacle* Receptacle 120V with one half of 240 V receptacle.
120V 5
2 Plug Wired for 240 V, 2-Wire
20 0 240V 6 Load
15 5 3 Neutral (Silver) Terminal
10 10 2
4 Load 1 (Brass)Terminal
5 15 3 5 Load 2 (Brass) Terminal
0 20 4 6 Ground (Green) Terminal
V x A = Watts
*One 240 V load or two 120 V loads. 7 Amperes Available using
120/240 V Plug
240V
Tools Needed:
6 5
ST-120 813-D

SECTION 7 – MAINTENANCE (ONAN-POWERED UNITS)
7-1. Routine Maintenance (Onan-Powered Units)
Y Stop engine before maintaining.
Recycle
. See Engine Manual and Maintenance Label. Ser-
engine vice more often if used in severe conditions.
fluids. * To be done by Factory Authorized Service Agent.
8h
Check fluid levels. Wipe up spills.

See Section 4-2. OIL
Full
20 h 25 h
Check and clean Service air filter wrapper

spark arrestor screen. (foam element). See
See Section 7-4. Section 7-3.
50 h
Clean cooling system. See Clean and
engine manual. tighten weld
terminals.
100 h
Change oil. See Change oil filter.
Section 7-5 and See Section 7-5
maintenance and maintenance
label. label.
Service air filter element. Clean and

See Section 7-3. tighten battery
connections.
200 h
Check valve Replace fuel

clearance.* filter. See
Section 7-5.
Replace
Check spark plugs. unreadable
labels.
500 h
Service welding generator

Repair or
brushes and slip rings.
replace cracked
Service more often in dirty
cables.
conditions.*
1000 h
Blow out or
vacuum inside.
Remove cylinder Clean crankcase OR
During heavy
head deposits.* breather valve.
service, clean
monthly.

7-2. Maintenance Label (Onan-Powered Units)
Follow the storage procedure in the engine owner’s manual if the unit will not be
NOTE used for an extended period.

7-3. Servicing Air Cleaner (Onan-Powered Units)
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element.
1 1 Wrapper (Foam Element)

Wash wrapper with soap and water
solution. Allow wrapper to air dry
2 completely.
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2 Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 1/97 – 156 852 / Ref. 185 095-A / S-0759
7-4. Servicing Optional Spark Arrestor (Onan-Powered Units)

Y Stop engine and let cool.
1 Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
Tools Needed:
1/4 in
801 942-C / Ref. 801 695-A / Ref. 203 073

7-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Onan-Powered Units)
1 Oil Drain Valve
2 1/2 ID x 12 in Hose
3 Oil Filter
Change engine oil and filter accord-
ing to engine manual.
Y Close valve and valve cap
before adding oil and run-
ning engine.
Fill crankcase with new oil to full
Full mark on dipstick (see Section 7-2).
4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Y Stop engine, tighten connec-
tions as necessary, and wipe
up fuel.
Tools Needed:
Ref. 801 942-C / 800 395-B / Ref. 203 073 / S-0842

7-6. Adjusting Engine Speed (Onan-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 ± 100 rpm Start engine and run until warm.
Turn A/V control to max.
3700 ± 50 rpm
Idle Speed Adjustment
1 Throttle Solenoid
2 Mounting Screw
6 Loosen two mounting screws.
3 Governor Arm
4 Carburetor
5 Idle Speed Screw
5 Pull governor arm away from
carburetor and hold while making
the following adjustment:
Left Side Turn idle speed screw until engine
runs at idle speed (see table).
Release governor arm. Place
Engine Control switch in Run/Idle
position.
6 Carburetor Stop
With solenoid energized, slide sole-
noid until idle speed screw just
touches carburetor stop. Tighten
solenoid mounting screws.
4 7 Governor Arm Extension

Check for smooth operation, and
10 8 7 1 readjust solenoid position if
necessary.
Weld/Power Speed Adjustment
2
Place Engine Control switch in Run
9 11 position.
3 8 Weld/Power Speed Rod
2
9 Locking Nut
Loosen nut.
10 Adjustment Nut
Top View
Turn adjustment nut until engine
runs at weld/power speed. Tighten
locking nut.
Y Stop engine.
11 Sensitivity Spring
See engine manual for governor
sensitivity adjustment.
Tools Needed:
1/4, 3/8 in
Ref. 801 942-C / 800 397-A

7-7. Overload Protection (Onan-Powered Units)
Y Stop engine.
Tools Needed: 1 Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote 14 receptacle RC1. If
CB5 opens, 24 volt ac output to
3/8 in RC1 stops.
RC1 stops.
5
Press button to reset breaker.
If CB5 or CB6 continues to open,
check remote device connected to
RC1.
3 Fuse F6 (See Parts List)
F6 protects the engine wiring sys-
tem from overload. If F6 opens,
engine will not crank.
If F6 continues to open, check
4 diodes D1 and D2, and Engine
Control switch S2.
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
3 weld and auxiliary power output
stops.
F2 protects the stator winding from
overload. If F2 opens, weld output
stops. Auxiliary power will still be
available.
Replace any open fuses. If F1 con-
tinues to open, check integrated
rectifier SR3. If F2 continues to
open, check integrated rectifier
SR2.
2 1 Reinstall cover before operating
unit.
801 945-C / Ref. 203 073

SECTION 8 – MAINTENANCE (KOHLER-POWERED UNITS)
8-1. Routine Maintenance (Kohler-Powered Units)
Y Stop engine before maintaining.
Recycle
. See Engine Manual and Maintenance Label. Ser-
engine vice more often if used in severe conditions.
fluids. * To be done by Factory Authorized Service Agent.
8h
Check fluid levels. Wipe up spills.

See Section 4-3.
OIL
20 h 25 h
Check and clean Service air filter wrapper

spark arrestor screen. (foam element). See
See Section 8-4. Section 8-3.
50 h
Clean and tighten
weld terminals.
100 h
Change oil. See
Section 8-5 and Service air filter element.
maintenance See Section 8-3.
label.
Clean cooling system. See Clean and

engine manual. tighten battery
connections.
200 h
Change oil filter.
Replace fuel
See Section 8-5
filter. See
and maintenance
Section 8-5.
label.
Replace
Check spark plugs. unreadable
labels.
500 h
Service welding generator
Repair or brushes and slip rings.
replace cracked Service more often in dirty
cables. conditions.*
1000 h
Blow out or vacuum inside. During OR

heavy service, clean monthly.

8-2. Maintenance Label (Kohler-Powered Units)
Follow the storage procedure in the engine owner’s manual if the unit will not be
NOTE used for an extended period.

8-3. Servicing Air Cleaner (Kohler-Powered Units)
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element.
1
1 Wrapper (Foam Element)
Wash wrapper with soap and water
2 solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2 Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 9/00 – 802 772 / Ref. 185 095-A / S-0759
8-4. Servicing Optional Spark Arrestor (Kohler-Powered Units)

1 Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
Tools Needed:
1/4 in
802 692 / Ref. 203 073

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)
1 Oil Drain Valve
2 1/2 ID x 12 in Hose
3 Oil Filter
Change engine oil and filter accord-
ing to engine manual.
Y Close valve and valve cap
before adding oil and run-
Full ning engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Y Stop engine, tighten connec-
tions as necessary, and wipe
up fuel.
Tools Needed:
802 692 / S-0842

8-6. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 ± 50 rpm Start engine and run until warm.
Turn A/V control to 10.
3700 ± 50 rpm Remove top cover to access speed
adjustments.
Idle Speed Adjustment
1 Move Engine Control switch to
Run/Idle position.
1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust
5 solenoid position so engine runs at
idle speed. If necessary, back out
2
4 idle speed screw so solenoid can
be moved to correct position. Tight-
en mounting screws. Be sure sole-
noid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4 Weld/Power Speed
Adjustment Nut
5 Lock Nut
Loosen lock nut. Turn adjustment
3 nut until engine runs at weld/power
speed. Tighten lock nut.
Reinstall top cover.
Y Stop engine.
Top View
Tools Need-
ed:
1/4, 3/8 in 802 692 / ST-801 209-A

8-7. Overload Protection (Kohler-Powered Units)
Y Stop engine.
Tools Needed:
3/8 in RC1 stops.
RC1 stops.
5
Press button to reset breaker.
If CB5 or CB6 continues to open,
check remote device connected to
RC1.
F6 protects the engine wiring sys-
tem from overload. If F6 opens,
engine will not crank.
If F6 continues to open, check
4 diodes D1 and D2, and Engine
Control switch S2.
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
weld and auxiliary power output
stops.
F2 protects the stator winding from
overload. If F2 opens, weld output
stops. Auxiliary power will still be
available.
Replace any open fuses. If F1 con-
3 tinues to open, check integrated
rectifier SR3. If F2 continues to
open, check integrated rectifier
SR2.
Reinstall cover before operating
unit.
2 1
802 694 / Ref. 203 073

SECTION 9 – THEORY OF OPERATION
1 Engine 12
Supplies force to turn revolving
field. Circuit
Breakers
2 Revolving Fields (Rotor) CB5, CB6
13
Turn at 3700 rpm maximum for weld
and power. The speed and excita- Output
11 (Contactor)
tion current of the field coils deter- Switch S4
mine voltages in stator windings. 14 15
Remote On
3 Stator Windings Remote Amperage/ A/V
Capacitor Voltage Switch S3 Control R1
Supply power to exciter, auxiliary Board PC4
power, and weld circuits. (Includes
Remote 14 Remote Panel
4 Integrated Rectifier SR3 Receptacle
Changes ac output of exciter stator RC1)
windings to dc to supply excitation
current to the exciter revolving field.
5 Fuse F1
Protects exciter excitation winding
from overload.
2 3
6 Field Current Control Board
PC2
Main Field Weld Windings
Auxiliary Power
Adjusts weld output by changing 1
revolving field current after compar-
Windings
ing feedback to selected amperage/ Revolving Fields
Engine (Rotor) Stator
voltage setting of R1.
7 Integrated Rectifier SR2
Field Supply
Changes ac output of exciter stator Exciter Field Windings
to dc to supply current to PC2.
8 Fuse F2 4 5
Protects exciter excitation winding
from overload. Integrated
Rectifier Fuse F1
9
9 Idle Module PC1 SR3
Controls engine speed. Without a Idle
Module
signal from CT1, it lowers engine PC1
speed to idle (2200 rpm). Throttle
solenoid TS1 is pull-to-idle.
10 Current Transformer CT1
Senses output from either auxiliary
power or weld windings, and signals
PC1 to increase to or maintain weld
speed (3700 rpm).
11 Capacitor Board PC4/Remote
14 Receptacle RC1
PC4 protects unit from high
frequency, and RC1 connects re-
mote amperage/voltage and con-
tactor control to unit.
12 Circuit Breakers CB5 And
CB6
Protect Remote 14 receptacle RC1
from overload.
AC Or DC Control Circuits
13 Output (Contactor) Switch S4
Selects On (panel) or Remote Weld Current Circuit
contactor control.
14 Remote Amperage/Voltage Mechanical Coupling
Switch S3
Magnetic Coupling
Selects Panel or Remote
amperage/voltage control.

15 A/V Control R1
Changes output of stator weld
windings by adjusting field current
level in revolving field.
6
16 Process Selector Switch S6
Selects unit output for welding
process.
17 Circuit Breakers CB1, CB3,
And CB4
Field 16
Current Protect 120 V and 240 V AC recep-
Control Process tacles RC1, RC2, and RC3 from
Board Selector overload.
PC2 Switch S6
18 120 V And 240 V AC Recep-
7 tacles RC1, RC2, And RC3
Provide connection points and
Integrated power for auxiliary equipment.
Rectifier
SR2 19 HF Filter Board PC3
Protects unit from high frequency.
20 DC Polarity And AC Switch
8 S1
Selects type and polarity of weld
Fuse F2 output.
21 Main Rectifier SR1
Changes ac input from weld
windings to dc with S6 in dc
position.
22 Shunt
Provides current feedback signal to
PC2.
23 Stabilizer DC-Z
10
Smooths out current to weld output
Current terminals.
Transformer
CT1 22 24 HF Filter Board PC5
Protects unit from high frequency.
20 Shunt
25 CC, CV, And Work Weld
17 17 Output Terminals
DC Polarity
And AC Switch Provide ac or dc weld output.
Circuit Circuit 21
Breakers Breaker S1
CB3, CB4 CB1 Main
AC DC Rectifier
SR1
19
HF Filter
Board 23
PC3
DC
Stabilizer
DC-Z 24
18 18
HF Filter
120 V AC 240 V AC DC Board
Receptacles Receptacle PC5
RC2, RC3 RC1
25 25 25
CC Weld CV Weld Work Weld
Output Output Output
Terminal Terminal Terminal
Electrode Work

SECTION 10 – EXPLANATION OF ELECTRICAL PARTS
elect_parts 1/01
10-1. Safety Precautions – Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.

D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
10-2. Explanation Of Electrical Parts

PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
CAPACITOR A device that stores electrical energy. Large

POLARIZED NON-POL.
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk” C1 C1
capacitors can be used for HF protection.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse CB1
that needs to be replaced when blown, a
circuit breaker can be reset.
DIODE A device that allows current to flow in one

direction only. Most common use is to D1
change AC to DC.
FUSE A protection device, usually an enclosed

piece of wire that melts and breaks the circuit F1
when the current exceeds the fuse rating.
HALL DEVICE Produces a small DC voltage proportional to

the current it is sensing (usually welding HD1
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
RESISTOR A device which resists the flow of electric FIXED R1

current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED TAPPED R1
POTENTIOMETER Both devices have a moveable brush that

OR makes contact along a resistor, allowing you
RHEOSTAT to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator VARIABLE R1
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.

PILOT LIGHT A light located on the front panel which

1
indicates if the machine is on or off.
PL
FAN MOTOR This device provides cooling of the internal

parts of a welding power source.
FM
VARISTOR A protection device whose resistance is

dependent on the voltage applied to it. In
normal operation it has a high resistance; VR1
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
GAS OR WATER These are electromechanical devices used to

SOLENOID start or stop the flow of shielding gas or
(VALVE) water. GS1
OR
WS1
RELAY––COIL AND This is an electromechanical device whose COIL

CONTACTS, contacts change state (the normally open
NORMALLY OPEN points close and the normally closed points
AND NORMALLY open) when proper voltage is applied to the
CLOSED coil. These contact points in turn may control CR1 CR1
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show NRM OPEN NRM CLOSED
the contact points in the power off state. POINTS POINTS
THERMOSTAT, This is a switch that closes its normally open

NORMALLY OPEN contacts (or opens its normally closed
AND NORMALLY contacts) when a preset temperature is TP1 TP1
CLOSED reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when NRM OPEN NRM CLOSED
needed and shutting off the output of a
welding power source if it is overheating.
CONTACTOR A heavy duty relay. Usually used to make

and break the welding arc or primary power.
COIL
W
W
NRM OPEN
POINTS
STABILIZER/ When placed in a DC circuit, the inductor or

REACTOR stabilizer as it is usually called, will oppose
any change in existing current. It is therefore Z1
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts L1
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.

MOTOR A device that is typically used to feed wire in

a MIG welding system.
B1
SHUNT A precision low-value resistor typically used

to supply a small voltage to drive an
SHUNT
ammeter.
MOSFET A device that is used as an “electronic D

switch.” When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
G
to control a relay, the speed of a motor, or
even the output of a welding machine. AS
S
IGBT A device that is used as an “electronic

switch.” When a signal is applied to the gate C1
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically G1 (B1)
used in “Inverter” designed welding machines
to control the welding output. E1
BRUSHES/SLIP Components that allow electrical connections

RINGS between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
TERMINAL STRIP An insulated connection point for wires. They

are used for the ease of making multiple
connections and can be a convenient point 42 42 104 105 74
1T
for making electrical checks when A B C D E
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
SWITCH A mechanical device that completes or SPST SPDT

breaks the path of the current or sends it over
a different path.
DPST DPDT

SCR A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current K
G
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to A
control the output to a load such as a welding
arc.
THERMISTOR A thermally sensitive resistor. The resistance

RT1
of a thermistor changes with a change in
temperature. Primarily used for “Fan on OR
Demand” and “Thermal Shutdown” circuits. TH1
TRANSFORMER A device that changes AC voltage from one

magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
T1
INTEGRATED An arrangement of four diodes used to AC +

BRIDGE change AC to DC. AC
RECTIFIER +
–
AC _ AC
SPARK GAP The arrangement of two electrodes between

which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding. G
CURRENT A transformer that produces an AC voltage CT1

TRANSFORMER used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in OR
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current. CT1

SECTION 11 – TROUBLESHOOTING
11-1. Troubleshooting Tables
. See Sections 11-2 and 11-3 for test
points and values and Section 14 and
following for parts location.
A. Welding Trouble
Trouble Remedy
No weld output. Check weld connections.
Check control settings.
Disconnect equipment from auxiliary power receptacles during start-up.
Check fuse F1, and replace if necessary (see Section 7-7 or 8-7).
If remote contactor is connected to Remote 14 receptacle RC1, place Output (Contactor) switch S4 in
Remote 14 position (see Sections 5-1 and 5-2).
Clean slip rings, and install new brushes if necessary (see Section 11-11).
Check integrated rectifier SR2, and replace if necessary.
Disconnect leads 33 and 24 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Check capacitor C1 for a short or open, and check for proper connections. Replace C1 if necessary.
Check diode D2, and replace if necessary.
Check main rectifier SR1, and replace if necessary.
Check shunt, and replace if necessary.
Check for open or shorted winding in weld stator, and replace if necessary.
Check Field Current Control Board PC2 and connections, and replace if necessary (see Section 11-7).
LED2 and LED3 on PC2 light when PC2 is energized.
Low weld output. Check control settings.

Increase A/V control R1 setting.
Clean air cleaner.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-6).
Disconnect stator leads 28 and 29, and check for continuity between leads. Replace stator if necessary.
Disconnect leads 33 and 24 from brushes, and check continuity across slip rings. Replace rotor if neces-
sary.

Check resistance and connections of A/V control R1; R1 is 0 to 1000 ohms ±10%. Replace R1 if
necessary.
Check Remote 14 receptacle RC1 for continuity and proper connections;, and replace RC1 if necessary
(see Section 4-9).
Check Capacitor Board PC4 and connections, and replace if necessary (see Section 11-9).
High weld output. Decrease A/V control R1 setting.

Check for obstructed movement of throttle solenoid TS1 linkage (see Section 7-6 or 8-6).

Trouble Remedy
Check resistance and connections of suppressor R3, VR1 if high open-circuit voltage is present. R3 is
1000 ohms ±10%. Replace R3, VR1 if necessary.
Erratic weld output. Check control settings.
Be sure electrode is dry and proper type for SMAW and GTAW.
Tighten and/or clean connections to electrode and workpiece.
Use correct wire and gas.
Check internal and external connections to weld output terminals.
Check leads and connections at DC Polarity/AC switch S1, and A/V control R1.
Remove excessive coils from weld cables.
Check stabilizer DC-Z for signs of failure. Check continuity across windings, and check for proper
connections. Replace DC-Z if necessary.
Weld output cannot be adjusted. Check position of Remote Amperage/Voltage switch S3.
Check resistance and connections of A/V control R1; R1 is 0 to 1000 ohms ±10%. Replace R1 if
necessary.
Remote contactor control does not Place Output (Contactor) switch S4 in Remote 14 position.
activate contactor.
Check circuit breaker CB5 (see Section 7-7 or 8-7).
Check and tighten connections to Remote 14 receptacle RC1 (see Section 4-9).
No power output at Remote 14 Reset circuit breaker CB5 and/or CB6 (see Section 7-7 or 8-7).
receptacle RC1.
Check internal and external connections to Remote 14 receptacle RC1 (see Section 4-9).
Lack of high frequency; difficulty in es- Use proper size tungsten for welding amperage.
tablishing Gas Tungsten Arc Welding
arc.
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connection. Repair or replace necessary parts.
Wandering arc – poor control of arc Use proper size tungsten.

direction.
Properly prepare tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Replace torch parts if water has leaked into torch.
maining bright after conclusion of weld.
Check and tighten all gas fittings.
Increase postflow time.
Shield weld zone from drafts.
Use clean filler rod or material.

B. Auxiliary Power Trouble
Trouble Remedy
No auxiliary power output. Reset circuit breakers (see Section 6-1).
Check diode D2, and replace if necessary.
Disconnect leads 33 and 24 from brushes, and check continuity across slip rings. Replace rotor if neces-
sary.
Disconnect stator leads 51 and 53 and check for continuity between leads. Replace stator if necessary.
Low power output. Check air cleaner and foam pre-cleaner; clean or replace as necessary.
Clean and adjust spark plugs and carburetor according to engine manual.
High power output. Check engine speed, and adjust if necessary (see Section 7-6 or 8-6).
Erratic power output. Check fuel level.
Check receptacle RC1, RC2, and RC3 wiring and connections.
Check governor according to engine manual.
Tune engine according to engine manual.
No auxiliary power output at Remote 14 Reset circuit breakers CB5 and/or CB6 (see Section 7-7 or 8-7).
receptacle RC1.
C. Engine Trouble
Trouble Remedy
Engine does not crank. Check fuse F6, and replace if open (see Section 7-7 or 8-7).
Check plug PLG5 and plug PLG8 connections.
Check continuity and connections of Engine Control switch S2. Repair or replace if necessary.
Check engine charging and starting systems according to engine service manual.
Engine will not start. Check fuel level.
Check battery, and replace if necessary.
Check continuity of Engine Control switch S2, and replace if necessary.
Check engine charging system according to engine manual.
Check fuel shutoff solenoid GS1 according to engine manual (GS1 standard on Kohler-powered units;
optional on Onan-powered, LP-fueled units).
See engine manual.
Engine starts, but stops when Engine Check oil level. Check Low Oil Pressure Shutdown switch S5 (see engine manual for location).
Control switch S2 returns to Run.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Sec-
tion 7-2 or 8-2).

Trouble Remedy
Battery discharges between uses. Turn Engine Control switch S2 to Off position when unit is not being used (see Section 5-1).
Clean battery terminals and posts with baking soda solution; rinse with clear water.
Recharge battery (approximately every three months).
Check battery, and replace if necessary.
Check voltage regulator according to engine manual.
Unstable or sluggish engine speeds. Check fuel level. Check fuel system components.
Readjust throttle linkage if necessary (see Section 7-6 or 8-6).
Tune engine according to engine manual.
Starter stays energized after Engine Check diode D1 and replace if necessary.
Control switch S2 is released.
Check polarity of battery connections (see Section 4-5).
Engine stops during normal operation. Check fuel level. Check fuel system components.
Check oil level. Check Low Oil Pressure Shutdown switch S5 (see engine manual for location).
Check fuel shutoff solenoid GS1 according to engine manual (GS1 standard on Kohler-powered units;
optional on Onan-powered, LP-fueled units).
Engine idles but does not reach weld Check solenoid linkage for obstructions, and readjust throttle linkage if necessary (see Section 7-6 or
speed. 8-6).
Check current transformer CT1, and replace if necessary.
Check idle module PC1 and connections, and replace if necessary (see Section 11-5).
Engine does not return to idle speed. Be sure Engine Control switch S2 is in Run/Idle position.
Remove weld/auxiliary power loads.
Be sure remote device connected to Remote 14 receptacle RC1 is turned off.
Check throttle linkage for smooth, non-binding operation.
Check resistance at throttle solenoid TS1.
Engine does not remain at weld/power Insufficient load; place Engine Control switch S2 in the Run position.
speed when power or weld load is ap-
plied with Engine Control switch S2 in
Run/Idle position.

11-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 11-3)
Test Equipment Needed:
See Section 4-9

for RC1 data
V5 V22, V21,
R9 R8 V20, R7
V23, R1
V6
V1,R4
See Section V3,
11-7 for V2 R5
PC2 data I2 I1
V25
See Section V4
11-9 for
PC4 data
V7
See Section
11-5 for PC1 V8
data
V9, V9,
R3 R3
V15
V14 V15
V14
Throttle Solenoid TS1 Throttle Solenoid TS1

(Pull-to-idle) (Pull-to-idle)

See Section 9 for PC3
information
V18, R11
V17, R10
V24,
R2
V19,
R12
R6 V10, V11
A, B, E, F
V12,
V13,
C, D
See Section
11-4 for
waveforms
A, B, C, D, E, F
See Section 9
for PC5 information
V16
203 082

11-3. Troubleshooting Values And Readings For Circuit Diagram (Use With Section 11-2)
Resistance Values Voltage Readings

a) Tolerance – ±10% unless specified a) Tolerance – ±10% unless specified
b) Condition – 70°F (21°C); cold machine b) Condition – 70°F (21°C); cold machine (no warm-up);
(no warm-up) CC mode; no load; weld/power rpm unless noted
c) Wiring Diagram – see Section 13 c) Reference – single arrow: reference to circuit common
d) Stop engine before checking resistance (lead 33); double arrow: reference to points indicated
R1 3.2 ohms d) Wiring Diagram – see Section 13
R2 32 ohms V1 170 volts ac
R3 11 ohms V2 DC input to Main Field with R1 at max: 245 volts dc
R4 thru Less than 1 ohm V3 23 volts ac
R12 V4 DC input to Exciter Revolving Field with R1 at max: 23
volts dc
V5 Contactor supply to PC2: with 24 volt contactor – 14 volts
Amperage Readings ac (idle rpm), 26 volts ac (weld/power rpm); with 115 volt
contactor – 67 volts ac (idle rpm), 132 volts ac
a) Tolerance – ±5% unless specified (weld/power rpm)
b) Condition – 70°F (21°C); cold machine V6 R1 input to PC2 at with S3 in Panel position: 0 volts dc
(no warm-up); no load (R1 at min); 10 volts dc (R1 at max)
I1 1.6 amps dc V7 Current sensing voltage with no weld/power load: 0 volts
ac; 100 ampere power load: 7.6 volts ac
I2 6.7 amps dc
V8 S2 in Run/Idle position: 12–14.5 volts dc ±5% (B is + and
E is –)
V9 No weld/power load: 12 volts dc (C is + and E is –) (S2 in
Run/Idle position); 0 volts dc (S2 in Run position)
V10 AC/CC OCV: 70 volts ac
V11 DC/CC OCV: 75 volts dc
V12 DC/CV with R1 in max: 42 volts
V13 DC/CV with R1 in min: 15 volts
V14 DC output from regulator (from center terminal on
regulator to ground): 14.2 volts dc ±5%
V15 AC input to regulator (two outside terminals on regulator):
35 volts ac (idle rpm); 54 volts ac (weld/power rpm)
V16 12.6 millivolts @ 100 ampere weld load
V17, V18 56 volts ac with R1 @ max
V19
V20, V21 130 volts ac
V22 26 volts ac
V23 23 volts dc
V24 55 volts dc
V25 14.5 volts dc

Notes

11-4. Waveforms For Section 11-2
2 ms 20 V 2 ms 5 V
gnd
gnd
A. DC/CC Mode, DC Open-Circuit Voltage B. DC/CC Mode, 25 Volts DC, 175 Amperes,
(Resistive Load)
2 ms 20 V 2 ms 20 V
gnd gnd
C. DC/CV Mode, DC Open-Circuit Voltage D. DC/CV Mode, 20 Volts DC, 170 Amperes,
(Resistive Load)

2 ms 50 V 2 ms 50 V
gnd gnd
E. AC/CC Mode, AC Open-Circuit Voltage F. AC/CC Mode, 25 Volts AC, 175 Amperes,
(Resistive Load)

11-5. Idle Module PC1 Testing Information
. An Onan-powered unit is
shown.
Use Section 11-6 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
1 Idle Module PC1
G E
Tools Needed:
3/8 in
Ref. 802 109-A

11-6. Idle Module PC1 Troubleshooting Flowchart
Y Stop engine before connecting or changing

meter leads and before replacing any parts.
Engine does not go to idle speed Engine does not go to weld/power speed
(2200 rpm) with no load applied. (3700 rpm) with load applied.
Connect meter (DC) between Connect meter (AC) between

terminal B (+) and terminal E (–). terminal G and terminal E.
Start engine, and place Engine Start engine, and place Engine
Control switch in Run/Idle position. Control switch in Run/Idle position.
Check connections
NO to Engine Control
Connect a 100 watt light bulb to
+12 volts dc present? switch S2 and
120 volts ac duplex receptacle.
ground connection
(lead 33).
YES
NO Check connections
Connect meter (AC) between
Minimum of 1 volt ac present? to current
terminal G and terminal E.
transformer CT1.
YES
Check for internal
NO
load such as Connect meter (DC) between
0 (zero) volts ac present?
shorted diode in terminal C (+) and terminal E (–).
main rectifier SR1.
YES
NO
Connect meter (DC) between Replace idle
0 (zero) volts dc present?
terminal C (+) and terminal E (–). module PC1.
YES
NO
Approximately +10 volts dc Replace idle Check throttle linkage for smooth
present after 12 to 18 seconds? module PC1. non-binding operation.
YES
Check throttle solenoid TS1, Disconnect 100 watt light bulb

and connections. and meter leads.
Reinstall cover. Reinstall cover.

11-7. Field Current Control Board PC2 Testing Information
shown.
Be sure plugs are secure before
testing. Use Section 11-8 for
specific values during testing.
1 Field Current Control Board
PC2
2 Plug PLG9
3 Receptacle RC4
4 Plug PLG1
5 Lead 46
6 Lead 45
7 Plug PLG3
8 LED3
9 LED2
10 LED1
LED2 and LED3 light when board is
energized.
LED1 is used for factory test
purposes only.
1
8 9 10
2
Ref. 802 109-A / 198 361

11-8. Field Current Control Board PC2 Test Point Values
a) Tolerance – ±10% unless

specified
b) Reference – to circuit common
(lead 33) unless noted
PC2 Voltage Readings
Receptacle Pin Value

PLG3 1 24 volts ac input with respect to pin 8 with Output (Contactor) switch S4 in On position (disconnect
remote controls from remote 14 receptacle RC1 when testing)
2 0 volts dc input with Process Select switch S6 in Wire position; +15 volts dc input with S6 in Tig or
Stick position
3 Circuit common
4 +10 volts dc output to A/V control R1
5 Circuit common
6 0 to +10 volts dc input from min to max of A/V control R1 with A/V switch S3 in Panel position
7 Circuit common
8 24 volts ac input with respect to pin 1 with Output (Contactor) switch S4 in On position (disconnect
remote controls from remote 14 receptacle RC1 when testing)
9 Circuit common
10 +15 volts dc output
11 +15 volts dc input with Process Select switch S6 in Tig position; 0 volts dc input with S6 in Wire or
Stick position
12 +14 volts dc input when engine is running
13 +12.6 millivolts dc input with respect to pin 14 at 100 amp weld load
14 +12.6 millivolts dc input with respect to pin 13 at 100 amp weld load
15 Not used
PLG1 1 +55 volts dc output with respect to pin 2 with A/V control R1 at max
2 Reference for main field voltage with respect to pin 1
PLG9 1 Not used
2 Not used
3 Not used
4 Not used
5 Circuit common
6 0 volts dc input with DC Polarity/AC switch S1 in AC position; +15 volts dc with S1 in DC position
7 Weld feedback input; same as CC or CV weld output terminal voltage with respect to pin 8
8 Weld feedback input; same as Work weld output terminal voltage with respect to pin 7
9 Not used
Lead 45 – + 250 volts dc input with respect to lead 46
Lead 46 – + 250 volts dc input with respect to lead 45

11-9. Capacitor Board PC4 Testing Information
shown.
2 1 Be sure plugs are secure before
testing. Use Section 11-10 for
specific values during testing.
RC2 1 Capacitor Board PC4
2 Receptacle RC2
3 Remote 14 Receptacle RC1
2
9
1
C2
10
K
C3
C5
C1
C7
C10
ASS’Y
C6
C
C9
C8
RC1
Ref. 802 109-A / 148 491-D
11-10. Capacitor Board PC4 Test Point Values

a) Tolerance – ±10% unless
PC4 Voltage specified
Readings
b) Reference – to circuit common
(lead 33) unless noted
Receptacle Pin Value
RC1 A 24 volts ac output
B Contactor control, 24 volts ac input
C Remote reference voltage, +10 volts dc output
D Remote control circuit common
E Remote command signal, 0 to +10 volts dc input from min to max of remote amperage/voltage control
R1
F Not used
G Circuit common for 24/115 volts ac circuit
H Not used
I 115 volts ac output
J 115 volts ac contactor control input
K Chassis common
RC2 1 Not used
2 Circuit common for 24/115 volts ac circuit
3 Not used
4 115 volts ac input
5 115 volts ac contactor control output
6 24 volts ac input
7 Contactor control, 24 volts ac output
8 Remote command signal, 0 to +10 volts dc output from min to max of remote amperage/voltage
control
9 Remote reference voltage, +10 volts dc input
10 Remote control circuit common

11-11. Replacing Brushes And Cleaning Slip Rings
shown.
1 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
2 Brush Holder
6 3 Brush With Spring
4 Brush Holder Cap
5 Brush Holder Retaining Bar
Mark and disconnect leads at caps
and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
1
Y Stop engine.
Install brushes, caps, bar, bracket,
and brush leads. Tighten bracket
2 hardware.
3
4
5/16 in (8 mm)
Minimum Length
9/16 in
(14.3 mm)
New Length
Replace
Damaged Brushes
Tools Needed:
7/32 in
9/16 in
3/8 in
802 109-A / S-0233-A

11-12. Checking Unit Output After Servicing
shown.
Check engine speeds, and adjust if
necessary (see Section 7-6 or 8-6).
1 120 Volt AC Receptacles RC2
And RC3
2 240 Volt AC Receptacle RC1
Check voltage at receptacles. With
no load applied, there should be
125 – 132 volts ac present at RC2
and RC3, and 228 – 264 volts pres-
ent at RC1.
3 Weld Output Terminals
Check open-circuit voltages
between terminals according to
Section 11-2 (voltages V10, V11,
V12, and V13).
If correct voltages are not present,
repeat troubleshooting procedures
in Section 11-1.
Complete pre-operational checks
in table. Reinstall cover and side
panels.
1
3
Pre-Operational Check
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged (see Parts List).
Check fuel and oil (see Section 4-2).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Tools Needed:
3/8 in
Ref. 802 109-A

SECTION 12 – DISASSEMBLY AND REASSEMBLY
12-1. Disassembly Of Unit
. As an alternative to the complete disassembly procedure

shown, the engine and rotor can be removed as one assem-
bly from the engine end. Remove brush assembly from end-
bell, support stator with blocks, and remove hardware hold-
ing stator to engine. Use a hoist to carefully lift the engine/ro-
tor assembly away from unit.
Tools Needed:
5/8 in
802 110-A / 802 111-A / 802 112
Disassembly AC Switch S1. Torque hardware as specified in Section

12-2.
Y Do not damage rotor or stator. Disassemble in sequence shown.
Reconnect stator leads as marked. Use
. An Onan-powered unit is shown. Y Use hoist and lifting strap to carefully cable ties to keep leads from sharp edges,
remove engine/generator assembly. and hot or moving parts.
Disconnect battery cables, fuel line, choke
Reassembly Reconnect fuel line, choke cable, and base
cable, and base ground cable. Remove
ground cable. Reinstall spark plugs, battery
spark plugs.
Reassemble unit in reverse order of and tray, panels, and cover. Reconnect
Mark and disconnect leads from DC Polarity/ disassembly. battery cables.

12-2. Disassembly Of Generator
1 Stator
2 Rotor Assembly
3 Bearing
4 Rotor Fan
5 Rotor Fan Adapter
6 Engine Adapter
7 Stud
8 Brush Holder Bar
9 Brush Holder Cap
10 Brush With Spring
11 Brush Holder
12 Brush Holder Bracket
13 Endbell
Torques:
14 O-Ring
A 15 ft lb (20 N.m)
B 20 ft lb (27 N.m)
C 25 in lb (3 N.m)
D 10 ft lb (14 N.m)
E 40 ft lb (54 N.m)
2 4
3 6
Apply pipe sealant
E (Loctite 59231) to
B two lower mounting
1
screws before
installing.
7
13
Apply SAE 30W oil
to both ends of studs
14 before installing.
12
D
11
C 10
9 8
ST-802 050

SECTION 13 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Trailblazer 280 NT LA095390 thru LB104520 199 560-A
LB104521 and following 203 082 See Table 13-1 (Onan) or

Table 13-2 (Kohler)
Circuit Board PC2 LA095390 and following 198 360
Circuit Board PC3 LA095390 and following 148 024-A

Figure 13-1. Circuit Diagram For Trailblazer 280 NT Eff w/LA095390 Thru LB104520
199 560-A

Figure 13-2. Circuit Diagram For Trailblazer 280 NT Eff w/LB104521 And Following
203 082

TP2
+SHUNT15V
D18
2 4
TP2 –BUS
D39
C74
D37
D22
+D15V
D28
8
TP2
11
12
SEC.
5
D38
T1
1
PRI. +15V
TP2
2
C71
3
–SHUNT15V R101
C55
D24
C62
D41
3 COM
1 TP2
W20 COM
SHUNTCOM TP1
1
+BATTERY 4
W40
D40
D23
D25 FLYBACK
C68
–15V
C64
C47
D36
5 VR1 4
C54
VIN SWITCH
RV1
C72
1 COMP F.B. R91

–BATTERY 1 2
W41 GND COM
COM
3
1
R90
R121
R102
W33
C63
C57
C69
COM
+10V
R92
R115
COM
+
3 A6 R112
D2
1
–
2 CV_CONTROL
U1
8
IN
7
R114
D S 6
R62
R118
D S 3 14 S D
GAIN_TEST R25
2 15
IN IN
1 16
U1 U1
CONTROL_REFA R111
+
5 A6 R113
7
–
6
TP2
6
R110
+10V
COM 1
R57 RC1
C79 +15V
12
+10V BUFFER 11
C36
U2
6 13
+15V – COM
7
U9 A3 R117
VIN VOUT 5
2 4 6 +
GND
11 S D
R119
10
IN
COM 9 U1
COM
2
– 1
3 A5
+
SHUNTCOM
Figure 13-3. Circuit Diagram For Field Current Control Board PC2 Eff w/LA095390 And Following (1 Of 2)
+15V
R96
L1
R97
+15V–A R105
C61
COM
8 U7
D20
D21
+15V 1
START R99
11 W120
R104
C66
R100
C81
+10V
COM 1
CONTACTOR
5 1 10–130VAC
D26
D27
CHARGE
6
PUMP
C59
C65
TP1
R36
2
OC1 1
5 4 10 3 2 4 W60
+ COM
3
A1
1
–
2
R95
R28
R2
R85
C51
C46
C27
C26
COM
COM
R1
R83
COM R74
C60
COM
COM
R84
C45
COM
R98
COM
CW
COM
POWER/GROUND NETS FOR CHIPS
A1–A4 4=+15V,11=–15V
A5 4=–SHUNT15V,8=+SHUNT15V
A6 4=COM,8=+15V
U1 U3 4=–15V,5=COM,12=+15V,13=+15V
U2 U6 7=COM,14=+15V
U4 4=–15V,5=COM,12=+15V,13=+15V
U5 8=COM,15=+15V
U8 9=+D15V,13=–BUS
OC2 5=–BUS,8=+D15V
198 360

ELECT 1 C5
Vfbr R8 VOLTAGE
W77
FEEDBACK
VOLTAGE FEEDBACK
R7 5
R31
C6 +1V=10V TP1
13 ABSOLUTE CIRCUIT 2
– 14 6 – 1
C3 12 A1 R13 – 7 3 A4
+ 5 A4 +
+ D7
COM
WORK 1
Vfbwk R4 COM
W76
R14
–1V=100A
+15V R32
R3
ABSOLUTE CIRCUIT 6
C4
13 – 7
R16 – 14 5 A2
COM 12 A2 +
D35
+ D4
LEM 1
Iofb W122 COM
C18 R17
U3
9
–15V IN
C19 10
D34
1
–15V U4 11 S D
–SHUNT15V
W123 8
–15V 9
IN
1 – 8 7
GND 10 A2
W124 6 S D +15V
+SHUNT15V
R88 +
+15V
+SHUNT15V CW
1 C8
+15V
W121
R87
STICK/TIG 1
COM AC
SELECT W127
R89
1 U3
D13
C29 IN
1 2
SHUNT + R77 R66 R46 R44 R64
W130
3 S D
C89
6
–
R45
7 R24
A5 9
D19
5
–
R94
+ 8
C48
–SHUNT15V 10 A4 R33
COM
+SHUNT15V +
COM
R120
D14
D15
C58
C90
R47
R48 R43
1
SHUNT – R93 1 COM
W131 3 5
4
11
TP1
U2
SHUNTCOM 2 U2
TIG 6
STICK/TIG 1 R51 8 START
W128 10
SELECT
U6
9 2
U6
R86
R50
3
1 R29
C88
C20
COM VOLTAGE_REGULATOR
AC
R23
R20
R19
COM C16
C44
5 COM
4
+15V
10
TP1
C87 U6 OCV REF

6 R34 R30
C17
–15V
R67
COM 13
R11
– 14
C91
R75
12 A4
D6
+
1
R52
AC/DC R78 Q2 R15 R12

SELECT W126
VOLTAGE REGULATOR
R53 2 COM
– 1
3 A2 R27
VOLTAGE DROOP
C41
+
R35
COM COM
R42
MIG=COM COM
STICK\MIG 1
SELECT W103
+10V
REF. 1
TCR1
SUPPLY W113
C35
CONTROL 1
SLOPE_AMP
COMMON W114 COM R39
VS1
C22
R41
1
REMOTE
8
W117 2
TP1
TCR3
COM – 1 13
3 A3 R37 – 14
STICK\MIG 1 + 12 A3
SELECT W104 +
R38
AC/DC 1 COM SLOPE CUT IN

R61
SELECT W125 COM SLOPE AMP
CHASSIS COM –15V
1
CONTROL_REF TCR2
W116
C82
VS2
C11
TP1
7 COM
TP1
12 COM
Figure 13-4. Circuit Diagram For Field Current Control Board PC2 Eff w/LA095390 And Following (2 Of 2)
1
C14 TP1
R22
+15V
FIELD_REGULA TOR
14 S D 9
R63 – 8
15
IN 10 A1 R70
16 + D11
R79
U4 +5V +15V
COM
LED1
R69
+5V
LED3
U5
COM
R81
R80
16 3
+5vREF OSC
PWM 12 6
TR 7
TP1 AC COM
11 TC
9
AE COMP
LED2
CC MIN CURRENT ADJUSTMENT 2 13 2
IN+
BC 1
14 IN–
BE 4
–15V R6 R5 10 SHUT– +SENSE
D17
D16
R82
5
OPTO 2 DOWN –SENSE
R72
C50
C49
C42
R26 COM RC1 7 PWM(4K HZ)
OPTO 2
3
OC2 –15V
TP1
D S6 6 3 COM
R76
7
IN TIG
13
U3 8 –BUS COM U6 START
Q3 R73
11
D12 12
D S 11
10 9
U2 COM
IN
R71
9 10
U4 8
GAIN_TEST
+BUS 1
COM RECT POS.
W45
C12 HI_GATE
RC1
4 Q4
R106
R109
CURRENT_REGULA TOR
C75
HI DRIVER
C52
D29
D33
9
R108
5
TP1 U8 RC1
7
D30
HO HI_COM
10 VB
6
C76
HIN 5 1
11
12
SD VS
3 W21 FIELD POS.
LIN VCC +D15V IFNEG
2
COM
1 6 1 FIELD NEG.
LO R107 RC1
C13 –BUS W24
R21 LO_GATE Q5
HIGHSIDE
DRIVER
D32
6
– 7 14 S D CC..NC
C73
C78
5 A1 R65
15
+ IN D31
16 U3
R18
COM CURRENTREGULA TOR +15V –BUS RC1 1 RECT NEG.

3 W46
R49
–BUS
2
D
U4 1
IN
S3
CC..NO
+15V
+15V–A
R68
C1
C9
C23
C30
C39
C43
C34
C53
C37
C28
C80
C67
COM
COM
C84
C2
C10
C24
C31
C38
C25
C33
COM
–SHUNT15V +SHUNT15V
U3 OC2
CV OPEN CIRCUIT REF. +D15V
+10V –15V
R56
R60
C77
C70
C85
C83
R54
R59
–BUS
SHUNTCOM
R58
COM 9
R40 – 8
10 A3
+
CV_CONTROL
COM CV CONTROL
REFERENCE
198 360

148 024-A
Figure 13-5. Circuit Diagram For HF Filter Board PC3
Eff w/ Serial No. LA095390 And Following
148 493-A
Figure 13-6. Circuit Diagram For Capacitor Board PC4

148 033-A
Figure 13-7. Circuit Diagram For HF Filter Board PC5
Table 13-1. Lead List Summary For Trailblazer 280 NT Models (Onan) Eff w/ Serial No. LB104521
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections

0001A RC5 (1) TO PLG8 0048A F2 TO SR2 (AC)
0002A RC5 (2) TO IDLE MOD (C) 0050A STATOR TO 1T–E
0005A RC5 (5) TO PLG8 0051A STATOR TO 1T–F
0006A RC5 (6) TO PLG8 0052A STATOR TO 1T–D
0007A PLG8 TO IDLE MOD (B) 0053A STATOR TO 1T–C
0020A D2 TO PLG3 (12) 0053E CB1 TO CB6
0020B HR METER (+) TO D2 0055A STATOR TO CT1 (4 TURNS) TO CB5
0020C PC2 (W20) TO RC3 (12) 0060A GFCI3 (NEUT) TO 1T (D)
0020D RC5 (3) TO HOUR METER (+) 0060B GFCI2 (NEUT) TO 1T (E)
0021A PLG1 (1) TO PC2 (W21) 0060C RC1 (W) TO 1T–E
0021B PLG10 (1) TO COM BRUSH 0060D 1T (E) TO PLG3 (1)
0021C RC6 (1) TO COM BRUSH 0060E PLG2 (2) TO 1T (E)
0021D SR3 (+) TO C1 (+) 0060E PC2 (W60) TO RC3 (1)
0021E RC10 (1) TO SR3 (+) 0060F STATOR TO 1T–D
0021F C1 (+) TO D2 0061A RC1(Y) TO CB1 (LOWER LOAD)
0021G RC1–1 TO R5 0061B CB3 TO CB1 (LOWER LOAD)
0021H R5 TO R4 0062A RC1 (X) TO PC3 (2)
0021J PLG6–1 TO R4 0062A RC1 (X) TO CB1 (UPPER LOAD)
0022A F1 TO SR3 (AC) 0062B CB4 TO CB1 (UPPER LOAD)
0024A PLG1 (2) TO PC2 (W24) 0062C RC1 (X) TO CB1 (UPPER LOAD)
0024B RC6 (2) TO MAIN BRUSH 0063A GFCI2 (HOT) TO CB3
0024C RC1–2 TO R5 0063B GFCI2 (HOT) TO PC3 (3)
0024D R5 TO R4 0064A GFCI3 (HOT) TO CB4
0024E PLG6–2 TO R4 0064B GFCI3 (HOT) TO PC3 (4)
0028A STATOR TO F1 0065A PLG2 (4) TO CB6
0029A STATOR TO SR3 (AC) 0066A CB5 TO S4
0033A PCI (E) TO GROUND 0066B PLG2 (6) TO CB5
0033A 1T (A) TO RC5 (4) 0070A STATOR TO SR1 (AC)
0033B IDLE MOD (E) TO 1T (B) 0070B S1 (2) TO SR1 (AC)
0033C RC1 (GR) TO GRD STUD 0071A STATOR TO S1 (3)
0033D SR3 (–) TO C1 (–) 0072A STATOR TO SR1 (AC)
0033E RC10 (2) TO SR3 (–) 0072B S1 (4) TO SR1 (AC)
0033F C1 (–) TO 1T (B) 0073A STATOR TO SR1 (AC)
0033G 1T–D TO CHASSIS GRD. 0074A S1 (8) TO SR1 (NEG)
0033H GRD. TO GRD. 0075A S1 (6) TO SR1 (POS)
0033I GFCI2 (GR) TO GND STRIP 0076A S1 (9) TO SHUNT
0033J GFCI3 (GR) TO GND STRIP 0076B PLG9 (8) TO S1 (9)
0033K GRD. STRIP TO PC4 0076C PC2 (W76) TO RC9 (8)
0033L PC2 (W33) TO RC3 (9) 0077A PC2 (W77) TO RC9 (7)
0033M GRD. STRIP TO PC5 0077B PLG9 (7) TO S1 (7)
0033N 1T (A) TO HOUR METER (–) 0077C DC–Z TO S6–7
0033O GND. STRIP TO GND. STUD 0078A S1 (1) TO ELECT (CC)
0033P IT (D) TO PLG3 (9) 0078B DC–Z TO ELECT CC
0033Q PLG10 (2) TO EXCITER BRUSH 0078C ELECT.(CC) TO PC5(2)
0033R GRD. STRIP TO PC3 0079A DC–Z TO CV
0040A PC2 (W40) TO RC4 (1) 0079B ELECT.(CV) TO PC5(3)
0041A PC2 (W41) TO RC4 (3) 0079C AUX
0043A STATOR TO SR2 (AC) 0079D AUX
0044A STATOR TO SR2 (AC) 0080A SHUNT TO WORK
0045A SR2 (+) TO PC2 (W45) 0080B WORK TO PC5(1)
0045C PC2 (C38+) TO C38+ 0103A PC2 (W103) TO RC3 (2)
0046A PC2 (W46) TO SR2 (–) 0103B PLG3 (2) TO S6
0046B PC2 (C38) TO C38–
Table 13-1. Lead List Summary For Trailblazer 280 NT Models (Onan) Eff w/ Serial No. LB104521 (Continued)
0104A PC2 (W104) TO RC3 (3) 0120B S4 (WIPER) TO PLG3 (8)
0104B PLG3 (3) TO S6 0121B PC2 (W121) TO RC9 (1)
0112A S4 TO PLG2 (5) 0122B PC2 (W122) TO RC9 (2)
0112B S4 TO PLG2 (7) 0123B PC2 (W123) TO RC9 (3)
0113A PC2 (W113) TO RC3 (4) 0124B PC2 (W124) TO RC9 (4)
0113B R1 (CW) TO PLG3 (4) 0125A PLG9 (5) TO S1 (10)
0114A PC2 (W114) TO RC3 (5)
0125B PC2 (W125) TO RC9 (5)
0114B R1 (CCW) TO PLG3 (5)
0126A PLG9 (6) TO S1 (11)
0115A PLG2 (8) TO S3
0126B PC2 (W126) TO RC9 (6)
0116A PC2 (W116) TO RC3 (6)
0127A PC2 (W127) TO RC3 (10)
0116B S3 WIPER TO PLG3 (6)
0117A PC2 (W117) TO RC3 (7) 0127B PLG3 (10) TO S6
0117B PLG2 (10) TO PLG3 (7) 0128A PC2 (W128) TO RC3 (11)
0118A R1 (CENTER) TO S3 0128B PLG3 (11) TO S6
0118B S3 (BOTTOM LEFT) TO S3 (CENTER RIGHT) 0130A PC2 (W130) TO RC3 (13)
0119A S3 TO PLG2 (9) 0131A PC2 (W131) TO RC3 (14)
0120A PC2 (W120) TO RC3 (8)

Table 13-2. Lead List Summary For Trailblazer 280 NT Models (Kohler) Eff w/ Serial No. LB104521
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.

0001A RC5 (1) TO PLG8 0048A F2 TO SR2 (AC)
0002A RC5 (2) TO IDLE MOD (C) 0050A STATOR TO 1T–E
0005A RC5 (5) TO PLG8 0051A STATOR TO 1T–F
0006A RC5 (6) TO PLG8 0052A STATOR TO 1T–D
0007A PLG8 TO IDLE MOD (B) 0053A STATOR TO 1T–C
0020A D2 TO PLG3 (12) 0053E CB1 TO CB6
0020B HR METER (+) TO D2 0055A STATOR TO CT1 (4 TURNS) TO CB5
0020C PC2 (W20) TO RC3 (12) 0060A GFCI3 (NEUT) TO 1T (D)
0020D RC5 (3) TO HOUR METER (+) 0060B GFCI2 (NEUT) TO 1T (E)
0021A PLG1 (1) TO PC2 (W21) 0060C RC1 (W) TO 1T–E
0021B PLG10 (1) TO COM BRUSH 0060D 1T (E) TO PLG3 (1)
0021C RC6 (1) TO COM BRUSH 0060E PLG2 (2) TO 1T (E)
0021D SR3 (+) TO C1 (+) 0060E PC2 (W60) TO RC3 (1)
0021E RC10 (1) TO SR3 (+) 0060F STATOR TO 1T–D
0021F C1 (+) TO D2 0061A RC1(Y) TO CB1 (LOWER LOAD)
0021G RC1–1 TO R5 0061B CB3 TO CB1 (LOWER LOAD)
0021H R5 TO R4 0062A RC1 (X) TO PC3 (2)
0021J PLG6–1 TO R4 0062A RC1 (X) TO CB1 (UPPER LOAD)
0022A F1 TO SR3 (AC) 0062B CB4 TO CB1 (UPPER LOAD)
0024A PLG1 (2) TO PC2 (W24) 0062C RC1 (X) TO CB1 (UPPER LOAD)
0024B RC6 (2) TO MAIN BRUSH 0063A GFCI2 (HOT) TO CB3
0024C RC1–2 TO R5 0063B GFCI2 (HOT) TO PC3 (3)
0024D R5 TO R4 0064A GFCI3 (HOT) TO CB4
0024E PLG6–2 TO R4 0064B GFCI3 (HOT) TO PC3 (4)
0028A STATOR TO F1 0065A PLG2 (4) TO CB6
0029A STATOR TO SR3 (AC) 0066A CB5 TO S4
0033A PCI (E) TO GROUND 0066B PLG2 (6) TO CB5
0033A 1T (A) TO RC5 (4) 0070A STATOR TO SR1 (AC)
0033B IDLE MOD (E) TO 1T (B) 0070B S1 (2) TO SR1 (AC)
0033C RC1 (GR) TO GRD STUD 0071A STATOR TO S1 (3)
0033D SR3 (–) TO C1 (–) 0072A STATOR TO SR1 (AC)
0033E RC10 (2) TO SR3 (–) 0072B S1 (4) TO SR1 (AC)
0033F C1 (–) TO 1T (B) 0073A STATOR TO SR1 (AC)
0033G 1T–D TO CHASSIS GRD. 0074A S1 (8) TO SR1 (NEG)
0033H GRD. TO GRD. 0075A S1 (6) TO SR1 (POS)
0033I GFCI2 (GR) TO GND STRIP 0076A S1 (9) TO SHUNT
0033J GFCI3 (GR) TO GND STRIP 0076B PLG9 (8) TO S1 (9)
0033K GRD. STRIP TO PC4 0076C PC2 (W76) TO RC9 (8)
0033L PC2 (W33) TO RC3 (9) 0077A PC2 (W77) TO RC9 (7)
0033M GRD. STRIP TO PC5 0077B PLG9 (7) TO S1 (7)
0033N 1T (A) TO HOUR METER (–) 0077C DC–Z TO S6–7
0033O GND. STRIP TO GND. STUD 0078A S1 (1) TO ELECT (CC)
0033P IT (D) TO PLG3 (9) 0078B DC–Z TO ELECT CC
0033Q PLG10 (2) TO EXCITER BRUSH 0078C ELECT.(CC) TO PC5(2)
0033R GRD. STRIP TO PC3 0079A DC–Z TO CV
0040A PC2 (W40) TO RC4 (1) 0079B ELECT.(CV) TO PC5(3)
0041A PC2 (W41) TO RC4 (3) 0079C AUX
0043A STATOR TO SR2 (AC) 0079D AUX
0044A STATOR TO SR2 (AC) 0080A SHUNT TO WORK
0045A SR2 (+) TO PC2 (W45) 0080B WORK TO PC5(1)
0045C PC2 (C38+) TO C38+ 0103A PC2 (W103) TO RC3 (2)
0046A PC2 (W46) TO SR2 (–) 0103B PLG3 (2) TO S6
0046B PC2 (C38) TO C38–
Table 13-2. Lead List Summary For Trailblazer 280 NT Models (Kohler) Eff w/ Serial No. LB104521 (Continued)
0104A PC2 (W104) TO RC3 (3) 0120A PC2 (W120) TO RC3 (8)
0104B PLG3 (3) TO S6 0120B S4 (WIPER) TO PLG3 (8)
0112A S4 TO PLG2 (5) 0121B PC2 (W121) TO RC9 (1)
0112B S4 TO PLG2 (7) 0122B PC2 (W122) TO RC9 (2)
0113B R1 (CW) TO PLG3 (4) 0124B PC2 (W124) TO RC9 (4)
0114A PC2 (W114) TO RC3 (5) 0125A PLG9 (5) TO S1 (10)
0114B R1 (CCW) TO PLG3 (5) 0125B PC2 (W125) TO RC9 (5)
0115A PLG2 (8) TO S3 0126A PLG9 (6) TO S1 (11)
0116B S3 WIPER TO PLG3 (6) 0127A PC2 (W127) TO RC3 (10)
0117A PC2 (W117) TO RC3 (7) 0127B PLG3 (10) TO S6
0117B PLG2 (10) TO PLG3 (7) 0128A PC2 (W128) TO RC3 (11)
0118A R1 (CENTER) TO S3 0128B PLG3 (11) TO S6
0118B S3 (BOTTOM LEFT) TO S3 (CENTER RIGHT) 0130A PC2 (W130) TO RC3 (13)
0119A S3 TO PLG2 (9) 0131A PC2 (W131) TO RC3 (14)

Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
TIG (GTAW) Welding

with SpectrumR Unit
and Gouging
Description
Trailblazer 280 NT
Eff w/LA095390 Thru LA289766
For OM-4402 (119 101) Revisions * And A

www.MillerWelds.com
SECTION 14 – PARTS LIST FOR LA095390 Thru LA289766
28
. Hardware is common and
29
not available unless listed.
23
30
22
27
21
24–Fig 14-3
26
18
20
31
25
19
55
17
16
36
15
35
14
34
37
32
13
33
38
12
11
44
52
10
43
42
45
9
39
46
47
48
8
44
49
40
45
41
50
7
47
51
6
1
5
4
2
3
54 – Fig. 14-2
53
ST-802 048-D
Figure 14-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
. . . 1 . . . . . . . . . . . . . 182 367 . . PANEL, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . ♦185 352 . . PANEL, right side stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 182 366 . . PANEL, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . ♦185 353 . . PANEL, left side stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +183 221 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +♦185 354 . . COVER, top stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 182 761 . . LABEL, general precautionary engine drive . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 192 042 . . LABEL, warning engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 181 881 . . GROMMET, neck filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 147 601 . . CAP, tank screw-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 183 433 . . PIPE, exhaust elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 183 314 . . CLAMP, muffler 1.625 dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 182 365 . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . ♦185 351 . . PANEL, rear upper stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 183 626 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 185 323 . . SEAL, baffle engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 159 914 . . UPRIGHT, base (Prior to LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 186 670 . . UPRIGHT, base (Eff w/LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 164 928 . . SEAL, barrel (Prior to LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 181 789 . . SEAL, barrel (Eff w/LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 183 166 . . PANEL, rear lower (Prior to LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 186 667 . . PANEL, rear lower (Eff w/LA114353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 165 271 . . VALVE, oil drain 3/8-18NPTF (included with engine) . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 165 623 . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 187 126 . . ENGINE, gas (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 183 434 . . . . MUFFLER, exhaust engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 065 313 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 059 926 . . . . PIN, spring CS .093 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . TS1 . . . 165 810 . . . . SOLENOID, 14VDC .53A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 165 522 . . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 868 . . . . INDICATOR/CAP ASSEMBLY (Dipstick) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦192 093 . . PUMP, electric fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . . . . . . . . . . . CONNECTOR, (Part of engine harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC5 . . . . 116 045 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG7, RC7 . . . . . . . . . . . CONNECTOR, (Part of engine harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . 174 823 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC10 . . . 174 824 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . Figure 14-3 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 167 730 . . CABLE, battery neg 29.00 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 165 600 . . CABLE, battery neg 18.50 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 182 935 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . +182 897 . . DOOR, access bat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 167 731 . . CABLE, bat pos 19.500 lg (included w/engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . Batt . . . 167 677 . . BATTERY, stor 12V 450crk 75rsv GP58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . +182 845 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 181 057 . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . DC-Z . . . 187 018 . . STABILIZER ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 020 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 625 . . . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 164 920 . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . SR1 . . . 183 051 . . RECTIFIER, si 3ph 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 182 928 . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 159 905 . . BRACKET, mtg engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 121 652 . . FILTER KIT, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 174 001 . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 14-1. Main Assembly (Continued)
. . . 39 . . . . . . . . . . . . . 182 079 . . TANK, fuel 10 gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 502 . . . . FITTING, stand pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 182 922 . . . . BUSHING, fuel tank 1.210 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 181 587 . . TRAY, pc board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . PC2 . . . 198 359 . . CIRCUIT CARD ASSEMBLY. field current controller . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . 174 823 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . C52 . . . 176 007 . . CAPACITOR, slectl 1200uf 300VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 176 199 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 44 . . . . . 1T . . . . 172 661 . . BLOCK, stud connection 6posn (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 734 . . . . JUMPER LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 45 . . . . . . . . . . . . . 172 731 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . F1, F2 . . *169 296 . . FUSE, mintr gls 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . SR2,3 . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . . . D2 . . . . 135 184 . . DIODE, board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . C1 . . . . 176 719 . . CAPACITOR, electl 1000uf 75VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . CT1 . . . 187 144 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . R4,5 . . . 139 812 . . RESISTOR, WW fxd 30W 5K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 53 . . . . . . . . . . . . . 180 628 . . PANEL, lower front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . Figure 14-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 197 930 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . F6 . . . . *021 718 . . FUSE, mintr gl 30A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 137 046 . . TUNE-UP & FILTER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 064 617 . . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 065 251 . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 121 652 . . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 065 709 . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Item Dia. Part
Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 54)
. . . 1 . . . . . . . . . . . . . 187 593 .. PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . R3,VR1 . . 046 819 .. SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . S1 . . . . 187 190 .. SWITCH, changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 187 189 .. BRACKET, shunt mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 030 080 .. SHUNT, meter 50MV 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R1 . . . . 072 623 .. POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S6 . . . . 088 409 .. SWITCH, toggle DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . 184 731 .. MODULE, pull to idle 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC4 . . . 147 554 .. CIRCUIT CARD ASSEMBLY, connector/receptacle . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S4 . . . . . 011 609 .. SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S3 . . . . . 011 611 .. SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB5,6 . . 083 432 .. CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . S2 . . . . 176 606 .. SWITCH, ign 4posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 177 859 .. CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 54) (Continued)
. . . 14 . . . RC2,3 . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125VAC . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . GFCI2,3 ♦147 939 . . RECEPTACLE, str dx grd 2P3W 15A 125VAC GFCI . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . PC3 . . . 148 021 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1,2 . . . 117 501 . . CIRCUIT BREAKER, man reset 1P 40A 250V . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . CB3,4 . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250V . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 19 . . . . . . . . . . . . . 073 756 . . STAND OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . 182 870 . . CONTROL, push pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 099 255 . . TERMINAL, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 601 836 . . NUT, brs hex jam .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 26 . . . . . . . . . . . . . 188 039 . . COVER, receptacle with gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 159 921 . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . RC1 . . . 182 954 . . RECEPTACLE, str 3P4W 50A 125/250VAC . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 119 172 . . PLUG, st 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 170 391 . . CAP, dust connector 9760-20 protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . HM . . . . 145 247 . . METER, hour 10-32VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 32 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 072 590 . . LOCK, shaft .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 115 493 . . HANDLE, range switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
5
. Hardware is common and 4
not available unless listed. 3
2 9
1 10
8
11
12
6 7
35
34 14
13
33 15
32 16
17
31
30
29 18
19
28
20
23 21
24
25
26
22
27
ST-802 049-B
Figure 14-2. Panel, Front w/Components

♦Optional
Item Part
No. No. Description Quantity
Figure 14-3. Generator (Figure 14-1 Item 24)
... 1 . . . . . . . . . . . . +186 238 . . STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 186 239 . . ROTOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 107 417 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 134 981 . . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 160 567 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 187 151 . . STUD, stl .375 -16 x 23.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 9 . . . . . . . . . . . . . 047 878 . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 161 306 . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 11 . . . . . . . . . . . . . *126 984 . . BRUSH, w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 12 . . . . . . . . . . . . . 005 614 . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 13 . . . . . . . . . . . . . 187 183 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 187 536 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 183 419 . . . . O-RING, 1.984 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 5
7
4
8
2
1
14
15
13
12
11
10 9 ST-802 050
Figure 14-3. Generator

Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
TIG (GTAW) Welding

with SpectrumR Unit
and Gouging
Description
Trailblazer 280 NT
Eff w/LA289767 Thru LB104520
For OM-4402 (119 101) Revisions B Thru G

www.MillerWelds.com
SECTION 15 – PARTS LIST FOR LA289767 THRU LB104520
28
29
23
30
22
27
21
24–Fig 15-3
26
18
20
31
25
19
55
17
16
36
15
35
14
34
37
32
13
33
38
12
11
44
52
10
43
42
45
9
39
46
47
48
8
44
49
40
45
41
50
7
47
51
6
1
5
4
2
3
54 – Fig. 15-2
53
ST-802 048-D
Figure 15-1. Main Assembly (Onan Engine Shown)

Item Dia. Part

. . . 1 . . . . . . . . . . . . . 182 367 . . PANEL, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 182 366 . . PANEL, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +183 221 . . COVER, top (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +183 222 . . COVER, top (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +♦185 354 . . COVER, top stainless (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +♦185 355 . . COVER, top stainless (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 147 601 . . CAP, tank screw-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 182 365 . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 183 626 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 186 670 . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 181 789 . . SEAL, barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 186 667 . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 165 623 . . LABEL, engine maintenance (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 173 088 . . LABEL, engine maintenance (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 187 126 . . ENGINE, (Onan) gas elec P220g–i/11592h (consisting of) . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 065 313 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 059 926 . . . . PIN, spring CS .093 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . TS1 . . . 165 810 . . . . SOLENOID, 14VDC .53A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 113 . . . . FILTER, fuel in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 200 762 . . ENGINE, (Kohler) gas elec CH20s–ps–64653 (consisting of) . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 189 477 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30 A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 167 730 . . CABLE, bat neg 29.00 lg no 4 awg w/clamp & .406 rng (Onan) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 165 600 . . CABLE, bat neg 18.500 lg 6ga w/.250 rng & .375 rng (Onan) . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 082 319 . . CABLE, cable,bat neg 17.750 lg no 4 awg w/clamp & .343 rng (Kohler) 1
. . . . . . . . . . . . . . . . . . . 172 669 . . CABLE, bat neg 11.000 lg 6ga w/.250 rng & .375 rng (Kohler) . . . . . . . . 1
. . . 27 . . . . . . . . . . . . +182 897 . . DOOR, access bat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 167 731 . . CABLE, bat pos 19.500 lg (Onan) (included w/engine) . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 173 921 . . CABLE, bat pos 28.000 lg no 4 awg w/clamp & .312 rng (Kohler) . . . . . . 1
. . . 31 . . . . . . . . . . . . +182 845 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 181 057 . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 187 020 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part

. . . 34 . . . . SR1 . . . 183 051 . . RECTIFIER, si 3ph 300 A (Prior to LB075979) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . SR1 . . . 202 222 . . RECTIFIER, si 3ph 300 A (Eff w/LB075979) (includes R3/VR1) . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 159 905 . . BRACKET, mtg engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 173 043 . . BRACKET, mtg engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 181 587 . . TRAY, pc board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 176 199 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 173 734 . . . . JUMPER LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . . . D2 . . . . 135 184 . . DIODE, board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 137 046 . . TUNE-UP & FILTER KIT (Onan) (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *064 617 . . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *065 251 . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *121 652 . . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *065 709 . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 180 096 . . TUNE-UP & FILTER KIT (Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 698 . . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067 007 . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . *067 272 . . . . AIR FILTER WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional


5
4
3
2 9
1
10
8
11
12
6 7
35
34 14
13
33 15
32 16
17
31
30
18
29
19
28
20
23 21
24
25
26
22
27
ST-802 049-B

Item Dia. Part
. . . 1 . . . . . . . . . . . . . 187 593 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . R3,VR1 . . 046 819 . . SUPPRESSOR (Prior to LB075979 only; Eff w/LB075979 R3/VR1 is
.............................. included with SR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . S1 . . . . 187 190 . . SWITCH, changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 187 189 . . BRACKET, shunt mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 030 080 . . SHUNT, meter 50MV 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R1 . . . . 072 623 . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S6 . . . . 088 409 . . SWITCH, toggle DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . 184 731 . . MODULE, pull to idle 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC4 . . . 147 554 . . CIRCUIT CARD ASSEMBLY, connector/receptacle . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S4 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S3 . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S2 . . . . 176 606 . . SWITCH, ign 4posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 177 859 . . CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1,2 . . . 117 501 . . CIRCUIT BREAKER, man reset 1P 40A 250V . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 073 756 . . STAND OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 601 836 . . NUT, brs hex jam .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 27 . . . . . . . . . . . . . 159 921 . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 119 172 . . PLUG, st 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . HM . . . . 145 247 . . METER, hour 10-32VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

Item Part
. . . 1 . . . . . . . . . . . . +186 238 . . STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 186 239 . . ROTOR ASSEMBLY (Prior to LA344379 – Onan; LA336113 – Kohler)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 201 516 . . ROTOR ASSEMBLY (Eff w/LA344379 – Onan; LA336113 – Kohler)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 107 417 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 134 981 . . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 160 567 . . ADAPTER, engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 172 683 . . ADAPTER, engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 187 151 . . STUD, stl .375 -16 x 23.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . 047 878 . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 161 306 . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 11 . . . . . . . . . . . . . *126 984 . . BRUSH, w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 12 . . . . . . . . . . . . . 005 614 . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 13 . . . . . . . . . . . . . 187 183 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 187 536 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 183 419 . . . . O-RING, 1.984 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 5
7
4
8
2
1
14
15
13
12
11
10 9 ST-802 050

Notes

Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
TIG (GTAW) Welding

with SpectrumR Unit
and Gouging
Description
Trailblazer 280 NT
Eff w/LB104521 And Following
For OM-4402 (119 101) Revisions H And J

www.MillerWelds.com
SECTION 16 – PARTS LIST FOR LB104521 AND FOLLOWING
28
29
23
30
22
27
21
24–Fig 16-3
26
18
20
31
25
19
55
17
16
36
15
35
14
34
37
32
13
33
38
12
11
44
52
10
43
42
45
9
39
46
47
48
8
44
49
40
45
41
50
7
47
51
6
1
5
4
2
3
54 – Fig. 16-2
53
ST-802 048-D
Figure 16-1. Main Assembly (Onan Engine Shown)

Item Dia. Part

. . . 1 . . . . . . . . . . . . . 182 367 . . PANEL, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 182 366 . . PANEL, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +183 221 . . COVER, top (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +183 222 . . COVER, top (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +♦185 354 . . COVER, top stainless (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +♦185 355 . . COVER, top stainless (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 147 601 . . CAP, tank screw-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 182 365 . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 183 626 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 186 670 . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 181 789 . . SEAL, barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 186 667 . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 165 623 . . LABEL, engine maintenance (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 173 088 . . LABEL, engine maintenance (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 187 126 . . ENGINE, (Onan) gas elec P220g–i/11592h (consisting of) . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 065 313 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 059 926 . . . . PIN, spring CS .093 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . TS1 . . . 165 810 . . . . SOLENOID, 14VDC .53A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 200 762 . . ENGINE, (Kohler) gas elec CH20s–ps–64653 (consisting of) . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 189 477 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30 A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 200 761 . . SHIELD, heat muffler (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 167 730 . . CABLE, bat neg 29.00 lg no 4 awg w/clamp & .406 rng (Onan) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 165 600 . . CABLE, bat neg 18.500 lg 6ga w/.250 rng & .375 rng (Onan) . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 082 319 . . CABLE, cable,bat neg 17.750 lg no 4 awg w/clamp & .343 rng (Kohler) 1
. . . . . . . . . . . . . . . . . . . 172 669 . . CABLE, bat neg 11.000 lg 6ga w/.250 rng & .375 rng (Kohler) . . . . . . . . 1
. . . 27 . . . . . . . . . . . . +182 897 . . DOOR, access bat (Prior to LB131533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . +201 174 . . DOOR, access bat (Eff w/LB131533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 167 731 . . CABLE, bat pos 19.500 lg (Onan) (included w/engine) . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 173 921 . . CABLE, bat pos 28.000 lg no 4 awg w/clamp & .312 rng (Kohler) . . . . . . 1
. . . 31 . . . . . . . . . . . . +182 845 . . BASE (Prior to LB131533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . +201 280 . . BASE (Eff w/LB131533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 181 057 . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Item Dia. Part

. . . . . . . . . . . . . . . . . . . 187 020 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . SR1 . . . 202 222 . . RECTIFIER,si 3ph 300 amp 400 piv 100% duty cycle . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 159 905 . . BRACKET, mtg engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 173 043 . . BRACKET, mtg engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 181 587 . . TRAY, pc board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 176 199 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 173 734 . . . . JUMPER LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . . . D2 . . . . 135 184 . . DIODE, board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 137 046 . . TUNE-UP & FILTER KIT (Onan) (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *065 251 . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *121 652 . . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *065 709 . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 180 096 . . TUNE-UP & FILTER KIT (Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 698 . . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067 007 . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . *067 272 . . . . AIR FILTER WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

5
4
3
1
10
8
11
12
6 7
36
35 14
13
34 15
33 16
17
32
31
18
30
19
29
20
23 21
24
25
26
27 22
28
ST-802 049-B

Item Dia. Part
. . . 1 . . . . . . . . . . . . . 187 593 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . S1 . . . . 187 190 . . SWITCH, changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 187 189 . . BRACKET, shunt mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 030 080 . . SHUNT, meter 50MV 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R1 . . . . 072 623 . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S6 . . . . 088 409 . . SWITCH, toggle DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . 184 731 . . MODULE, pull to idle 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC4 . . . 147 554 . . CIRCUIT CARD ASSEMBLY, connector/receptacle . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S4 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S3 . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S2 . . . . 176 606 . . SWITCH, ign 4posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 177 859 . . CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1 . . . 202 683 . . CIRCUIT BREAKER, man reset 2p 40a 240vac screw–90 . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 073 756 . . STAND OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 601 836 . . NUT, brs hex jam .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 27 . . . . . . . . . . . . . 203 016 . . BOOT, circuit breaker 2-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 159 921 . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 119 172 . . PLUG, st 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . HM . . . . 145 247 . . METER, hour 10-32VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

Item Part
... 1 . . . . . . . . . . . . +186 238 . . STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 201 516 . . ROTOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 107 417 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 134 981 . . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 160 567 . . ADAPTER, engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 172 683 . . ADAPTER, engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 187 151 . . STUD, stl .375 -16 x 23.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 9 . . . . . . . . . . . . . 047 878 . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 161 306 . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 11 . . . . . . . . . . . . . *126 984 . . BRUSH, w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 12 . . . . . . . . . . . . . 005 614 . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 13 . . . . . . . . . . . . . 187 183 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 187 536 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 183 419 . . . . O-RING, 1.984 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 5
7
4
8
2
1
14
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13
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10 9 ST-802 050

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA  2001 Miller Electric Mfg. Co.

Trailblazer 280 NT

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Trailblazer 280 NT

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TM-4402B October 2001

Eff. w/Serial Number LA095390

TIG (GTAW) Welding

Air Plasma Cutting and Gouging

Engine Driven Welding Generator

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1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.

MOVING PARTS can cause injury.

Trailblazer 280 NT TM-4402 Page 1

1-3. EMF Information

TM-4402 Page 2 Trailblazer 280 NT

Start Engine Panel/Local Temperature Fuel

Do not switch while Remote 14

Trailblazer 280 NT TM-4402 Page 3

C 3/4 in (19 mm) E

F 45-1/2 in (1156 mm) 25° 25°

Onan: 591 lb (268 kg)

3-3. Fuel Consumption While Welding

TM-4402 Page 4 Trailblazer 280 NT

OUTPUT AT 100% DUTY CYCLE (KW)

3-5. Auxiliary Power Curve

AC POWER AMPERES AT 120V

AC POWER AMPERES AT 240V

Trailblazer 280 NT TM-4402 Page 5

TM-4402 Page 6 Trailblazer 280 NT

100% Duty Cycle at 280 Amperes DC Duty cycle is the percentage of 10

18 in Y Always securely fasten

Electrically bond genera-

Trailblazer 280 NT TM-4402 Page 7

. Follow run-in procedure in engine

. This unit has a low oil pressure shut-

Use correct grade oil for cold

Ref. 151 983 / 801 942-C / Ref. 800 395

TM-4402 Page 8 Trailblazer 280 NT

. Follow run-in procedure in engine

. This unit has a low oil pressure

Full Use correct grade oil for cold

801 221 / 802 692

Trailblazer 280 NT TM-4402 Page 9

. When electrolyte is low, add

5 A For 30 Minutes Tools Needed:

TM-4402 Page 10 Trailblazer 280 NT

Y Connect negative (–)

4-6. Installing Exhaust Pipe

4-7. Connecting To Weld Output Terminals

801 943-B / Ref. 203 073

Trailblazer 280 NT TM-4402 Page 11

2 ea. 2/0 2 ea. 2/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

4-9. Remote 14 Receptacle Information

Socket* Socket Information

C 0 to +10 volts dc output to remote control.

G Circuit common for 24 and 115 volt ac circuits.

*The remaining sockets are not used.

TM-4402 Page 12 Trailblazer 280 NT

Trailblazer 280 NT TM-4402 Page 13

Ref. 203 073

TM-4402 Page 14 Trailblazer 280 NT