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Issued Jan. 2014 Index No. ED/4.78Trailblazer 302 Air Pak anceRepairStructural Steel WorkSheet Metal Gas Engine-Driven Welder/AC Generator/Air Compressor/12/24 V Battery Charge/Jump StartProcesses (X-Ray Quality)Output RangeStick (SMAW)MIG (GMAW)Flux-Cored (FCAW)AC/DC TIG (GTAW)Battery Charge/Jump StartAir Carbon Arc (CAC-A) Cutting and GougingRated: 3/16-inch carbons,Capable: 1/4-inch carbonsAir Plasma Cutting and Gouging withoptional Spectrum modelsRated: 5/8-inch mild steelDC Stick25– 300 AAC TIG/Stick 10 – 225 ADC TIG10 – 300 AMIG/FCAW 13 – 35 V, 350 AGenerator Power Output Rated at 104 F (40 C)Peak: 13,000 W — Continuous: 11,000 WAir Compressor31 CFM, 100% Duty Cycle, 80 – 160 PSIBattery Charge/Jump StartBattery Charge: 12/24 V, 10–75 ABattery Jump Start: 12/24 V, 450 A /350 AEasy to service.Toolless top access to: Engine air cleaner Engine oil check/fill dipstick Battery Compressor oil check/fill dipstick Compressor oil separator Air compressor air filterThe all-in-one tool thatdelivers multiprocessoutput for welding,plasma cutting, gouging,air tools, and 12/24-voltbattery charge/jump start.Toolless side access to: Engine oil filter Engine oil drain Engine fuel filterEasy operation. Reduce fuelconsumption and noise byusing the front panel air flowcontrol which matchesengine speeds to air flowrequirements for tools,plasma cutting and gouging.Rear access to: Compressor oil filter Compressor oil drainFront panel air pressure adjustment. Simple to adjust the correctair pressure for specific applications(80 –160 PSI) Lower pressure will increase enginepower for more gouging and plasmacutting output capabilitiesWelder/generator/air compressor/battery charger iswarranted for 3 years, parts and labor. Engine iswarranted separately by the engine manufacturer.Miller Electric Mfg. Co.Equipment Sales US and CanadaAn ITW Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USAPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125MillerWelds.com

Trailblazer 302 Air Pak Features Size and WeightBattery Charge/Jump StartTakes only half the bed space of a separateengine-driven air compressor and welder,freeing up to 50 percent more room on yourtruck for equipment and supplies. Plusdecreases axle weight up to 25 percent. Provides selectable 12- or 24-voltbattery charging capability Provides up to 450 amps ofbattery jump-starting capability Convenient front panel batterycharge/jump start access 25-foot battery jumper cablesavailable (#300 422)Independent Weld and Generator AdvantagesIndustrial Rotary-Screw Air Compressor 13,000 watts of voltage-regulated power No interaction between grinders, power tools, etc. and thewelding arc Generator power is independent of weld Four-pole weld generator produces the best arc quality Runs most air impact wrenches at idle Produces 31 CFM of air at 100 percent duty cycle Delivers 80 –160 PSI of air with no storage tank Gives 100 percent deliverable air Compressor is warranted by Miller for three yearsWeld PowerGenerator Power2

Answers to Frequently Asked Trailblazer 302 Air Pak Questions Air FactsWhat Does Average vs Continuous CFM Mean? Moisture going into a compressor also comes out. Air compressors heat air, turning moisture droplets into vapor. Air tools are often rated as “Average CFM.” Average CFM istypically based on 15-second usage intervals.Impact wrenches, button punch/deck tools, and decking crimptools are typically used intermittently (short time durations). Continuous CFM: This rating is based on continuous usage.Air grinders and sand blasters are examples of air tools that areused continuously.How Can I Reduce Moisture in the Air?Air Cooler with Separator #300 420 Most popular. The cooler cools air which turns vapormoisture into droplets and the separatorremoves the droplets. Removes 70 percent of the moisture fromthe air. Use for most applications including tools,blasters, plasma cutters and gouging. Effective when temperatures are above freezing (this is alsowhen the most moisture is in the air). Below 32 degreesFahrenheit (0 C) the separator can freeze. If this happens,bypass the cooler/separator system and continue air operationswithout drying it. Fully integrated inside of the Air Pak.RTI Filter #300 491 Recommended for plasma cutting. Separatorsremove droplets of water, not vapor, but this isgood enough for most plasma cutting applications. Because compressors heat air, this filter option isless effective at removing moisture (heat turnsdroplets into vapor and vapor is not filtered).The Air Pak Will Easily Run the Following:Air ToolsAverageCFM*ContinuousCFM*3/4-inch Impact Wrench (IR 2141)10403/4-inch Impact Wrench (Speedaire)7261/2-inch Impact Wrench (IR 231C)422Needle Scaler (IR 182LNA1)3134-1/2-inch Grinder (Dayton)7261/4-inch Die Grinder (IR G1H350RG4)6251/2-inch Drill (IR 7AQSTB)417Air Shears (IR 7802SA)421Sand Blaster—6Soda Blaster—18Button Punch/Deck Tool—4Decking Crimp Tool415*1/2-inch air hose is recommended for better tool efficiency.Note: Impact wrenches use Continuous CFM when “free” spinning.In actual use, CFM requirements are less. Thus, the Trailblazer Air Pakis rated to run a 40 CFM impact wrench.Desiccant Air Dryer #300 690 Cools air and removes 99 percent of themoisture from the air. Primary use is when temperature rangesbelow freezing and moisture still must beremoved from the air. Has a built in heater. Mounted externally from the machine with some wiring thatneeds to take place inside of the machine.How Do I Access the Air?The Trailblazer Air Pak provides four convenient air compressoraccess points. The air outlet connection requires a 1/2-inchNPT swivel fitting.Note: Reduces air flow up to four CFM at all speeds.WATER IN AIR (g/ft.3)MAX FLOW ABSOLUTE HUMIDITY1050050100150DRYER AIR PRESSURE (PSI)Air Cooler with Separator (#300 420)Desiccant Air Dryer (#300 690)No Air Cooler or Dryer3

Specifications (Subject to change without notice.)WeldingModeProcessAmp/VoltRangesRated Weld Outputat 104 F (40 C)*Single-PhaseGenerator PowerSound Levels atRated Output 7 m (23 ft.)CV/DCMIG/FCAW13– 35 V300 A at 32 V, 100% Duty Cycle350 A at 32 V, 60% Duty Cycle2400 RPM (Idle)73.4 dB (98.4 Lwa)CC/DCStick/TIG10– 300 A280 A at 32 V, 100% Duty CycleCC/ACStick/TIG10– 225 A200 A at 25 V, 60% Duty Cycle12/24 VCharge: 10 – 75 AJump Start: 450 A, 12 VJump Start: 350 A, 24 VPeak:13,000 wattsContinuous:11,000 watts120/240 VAC,100/50 A, 60 HzBattery Charge/Jump Start*Rated at sea level. **Net weight without fuel.NetWeight**DimensionsH: 28 in. (838 mm)H: 34.5 in. (876 mm)(to top of exhaust)W: 20 in. (508 mm)D: 59.625 in. (1514 mm)3000 RPM76.5 dB (101.5 Lwa)3600 RPM81.2 dB (106.6 Lwa)771 lb.(350 kg)Certified by Canadian Standards Association to both the Canadian and U.S. Standards.Air Compressor SpecificationsCompressorBrand andWarrantyFeaturesMiller,3-yearwarrantyRotary screw with electricclutch for on/off. Oil changeintervals 500 hours.Free AirDelivery at3600 RPMFree AirDelivery at3000 RPMFree AirDelivery at2400 RPM utomaticCompressorShutdowns31 CFM(0.88 m3/min.)28 CFM(0.79 m3/min.)22 CFM(0.62 m3/min.)80–160 PSIG100%1.75 qt.(1.7 L)High Pressure(160 PSI)Engine Specifications (Engines warranted separately by the engine manufacturer.)Engine Brandand WarrantyHorsepower tandardShutdownsKohler CH750,3-year warranty27 HP at3600 RPMTwin-cylinder, four-cycle overheadvalve, industrial air-cooled, gasoline*3600/3000RPM2400RPM12 gal.(45 L)1.75 qt.(1.7 L)Low OilPressure*Fuel stabilizer is recommended for gas engines that are used infrequently.Performance DataAIR COMPRESSOR FUEL CONSUMPTION(at 100% Duty Cycle)WELD/GENERATOR FUEL CONSUMPTION2.251.22.001.11.75US GAL./HR.1.00.9US 0.000.2IDLE050100 150 200250 300 350 400DC WELD AMPS AT 100% DUTY CYCLE0.10.0240030003600024681012GENERATOR POWER IN KILOWATTS AT100% DUTY CYCLEENGINE SPEED RPMFUEL CONSUMPTION DATA 12-gallon fuel capacity. On a typical job using 1/8-inch 7018electrodes (125 A, 20% duty cycle) expectover 16 hours of operation. Welding at 150 A, 40% duty cycle usesapproximately: 3/4-gallon per hour —over 13 hours of operation. Many air tools can be used when running atidle. Running at idle with a compressor loadwill provide 14 hours of run time. Running the air compressor at 31 CFM willprovide 11 hours of run time. Reduce fuel consumption by turning the aircompressor off when the Air Pak is not in use.For weld/generator fuel consumption chart seechart at left.Mounting SpecificationsA4 HolesEngine EndGBCDEF4A. 20 in. (508 mm)B. 16.5 in. (419 mm)C. 1.75 in. (44 mm)D. 6.062 in. (154 mm)E. 32.75 in. (832 mm)F. 59.625 in. (1514 mm)G. .406 in. (10 mm) diameterHeight: 28 in. (838 mm)34.5 in. (876 mm)(to top of exhaust)Width: 20 in. (508 mm)Depth: 59.625 in. (1514 mm)Lifting eye rating:1000 lb. (453 kg)

Function and Benefit Guide1829341056111271314*Category Exclusive1. Self-calibrating digital weld meters withmeter maintenance displays capable ofdisplaying engine and air compressor oilchange intervals.5. Lift-Arc TIG with Auto-Crater * andAuto-Stop *2. Four preset DIG settings* offer the bestarc characteristics for different electrodesand joint designs. The amount of DIGdetermines how much amperage (heat)varies with Stick arc length. The combinedProcess switch along with preset DIGsettings make the Trailblazer easy to setwithout the complication of multiple switches.7. Air pressure gauge/regulator gives theapproximate air pressure settings neededfor common air tools/plasma/carbon arcgouging. The pressure gauge also reads theactual air pressure being used. The regulatorallows user control of the pressure settingsup to 160 PSI.3. Adaptive Hot Start * (Stick) automaticallysets starting amperage for great arc starts.4. Great MIG/FCAW performance and arcstarts make the Trailblazer’s arc best in itsclass. Easy to run all wires from .023-inchsolid wires to large diameter 5/64-inchflux-cored wires.6. Air compressor, battery charge/jump start,and maintenance selector8. Front panel fuel gauge* LEDs indicate fuellevel. The “E” LED lights when fuel is low.9. AC/DC and battery charge/jump startswitch allows selection between AC orDC weld output and battery charge/jump function.10. Battery charge/jump start receptaclefor connection to battery charge/jump cable(12 or 24 volt).11. Standard 14-pin receptacle for simpleconnection of remote controls and wirefeeders. It features Auto Remote Sense *which automatically switches from Panel toRemote Amperage/Voltage (A/V) controlwith remote connected. Eliminatesconfusion of the Panel/Remote A/V switch.12. Speed control switch allows for control ofengine speed based on the switch position.In the auto speed mode, the speed will beauto selected depending on total powerneeded. The speed will auto select between3000 and 3600 RPM depending on welddemand or weld plus air demand. Anytimeauxiliary load is needed the engine will go to3600 RPM.13. Engine choke control14. 120 VAC and 240 VAC receptacles withcircuit breakersNote: For matching plug, order #119 172.5