Miller Electric 301 G manual

Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding Engine Driven Welding Generator OM-4411 207 283E May 2004 Miller Legend 301 G  V isit our website at www.MillerWelds.com MIG (GMAW) W elding & Flux Cored (FCAW ) Welding - With V oltage Sensing Feeder[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label 30 . . . . [...]

OM-441 1 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special s[...]

OM-441 1 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the ar[...]

OM-441 1 Page 3 STEAM AND HOT COOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is needed, and there is no overflo[...]

OM-441 1 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga-[...]

OM-441 1 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03  A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés pa[...]

OM-441 1 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du procédé de soudage g?[...]

OM-441 1 Page 7 L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outils[...]

OM-441 1 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.  Ne pas brancher[...]

OM-441 1 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil Engine Choke Check V alve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V V olts MIG (GMAW), Wire Stick (SMAW) TIG (GT A W) Circuit Breake[...]

OM-441 1 Page 10 SECTION 4 − SPECIFICA TIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and D C wel d out - put for quiet, fuel-ef ficient operation. At 1800 rpm, this unit produces 5 kW/kV A 60 Hz 120/240 V olt AC generator power . Achieve high quality Stick and TIG welding resu[...]

OM-441 1 Page 1 1 4-4. Fuel Consumption While W elding And Using Generator Power 207 967 3000 RPM Weld 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 100 150 200 250 300 DC WELD AMPERES A T 100% DUTY CYCLE U.S. GAL./HR. 1.98 0.95 2.84 3.78 5.67 4.73 6.62 7.57 LITERS/HR. 0.00 3600 RPM Weld Generator at 5 kW Generator at 4 kW Generator at 2 kW Genera[...]

OM-441 1 Page 12 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 100% Duty Cycle at 280 Amperes DC/CC Continuous Welding 4-6. Duty Cycle Ref. 207 925 01 0 20 30 40 50 60 100 70 80 90 150 175 200 225 250 275 300 % DUTY CYCLE WELD AMPERES 325[...]

OM-441 1 Page 13 207 970 / 207 971 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. A. CC/DC Stick Mode B. CV/DC MIG Mode 4-7. Stick And MIG Mode V olt-Ampere Curves 3600 RPM 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 2[...]

OM-441 1 Page 14 204 930 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. 4-8. DC TIG Mode V olt-Ampere Curves 0 5 10 15 20 25 30 35 40 45 50 0 50 100 150 200 250 300 350 DC AMPERES DC VOL T S Notes W or k l i ke a P r o! [...]

OM-441 1 Page 15 SECTION 5 − INST ALLA TION install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274  Do not weld on base. W elding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other appli[...]

OM-441 1 Page 16 5-2. Engine Prestart Checks 803 129 Full 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. Chec[...]

OM-441 1 Page 17 5-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minut[...]

OM-441 1 Page 18 5-4. Connecting The Battery Ref. 800 394-C / Ref. 21 1 909 / Ref. S-0756-D + − 3/8, 1/2 in  Connect negative ( − ) cable last. T ools Needed: 5-5. Installing Exhaust Pipe 801 681 / Ref. 21 1 909  Stop engine and let cool.  Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe to- ward co[...]

OM-441 1 Page 19 5-6. Connecting T o Weld Output T erminals  Stop engine.  Do not connect to CC and CV terminals at the same time. 1 Negative ( − ) W eld Output T erminal 2 Stick/TIG (CC) W eld Output T erminal 3 Wire /CV W eld Output T erminal Fo r MIG welding, connect work cable to Negative ( − ) terminal and wire feeder cable to Wire ([...]

OM-441 1 Page 20 5-8. Remote Receptacle Information Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to the remote receptacle is running. NOTE Socket* Socket Information AJ 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB5. AJ B K I B Not used. C L NH D M G 1 15 VOL TS AC I 1 15 volts ac. Protected by fuse F2 D M [...]

OM-441 1 Page 21 5-9. Adjusting Wire (MIG) Weld Puddle Consistency Ref. 803 100 3/8, 7/16 in T ools Needed: 1 2 3  Stop engine and let cool. Stabilizer DC-Z is factory connected to suit most Wire (MIG) welding applica- tions. T o change Wire (MIG) weld puddle con- sistency , proceed as follows: Remove cover and right side panel. 1 Stabilizer DC-[...]

OM-441 1 Page 22 SECTION 6 − OPERA TING WELDING GENERA T OR 6-1. Front Panel Controls 2 1 4 3 Ref. 21 1 909 7 5 6[...]

OM-441 1 Page 23 6-2. Description Of Front Panel Controls 1 Process Switch Se e Section 6 -3 for Process switch informa- tion. 2 V oltage/Amperage Adjust Switch And Remote Receptacle Use switch to select front panel or remote voltage/amperage control. For remote con- trol, place switch in Remote position and connect remote control to Remote recep- [...]

OM-441 1 Page 24 6-3. Process Switch 1 Process Switch  W eld output terminals are ener- gized whenever the engine is run- ning.  The unit will not return to idle speed when the remote contactor is on (clo- sure between pins A and B on remote receptacle). Use switch to select weld process (see table be low and Section 5-8). Use Stick position [...]

OM-441 1 Page 25 6-4. Remote Amperage/V oltage Control 1 Remote Receptacle RC4 Connect optional remote control to RC4 (see Section 5-8). 2 Remote Hand Control (Optional) 3 Remote Foot Control (Optional)  Engine runs at weld speed when a device connected to the remote receptacle makes closure be- tween pins A and B (example: trigger pull on MIG g[...]

OM-441 1 Page 26 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Circuit Breakers Ref. 21 1 909  If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.  Weld output and 60 Hz generator power output at receptacles RC1 and RC2 are not available at the same time. When welding, gen- e[...]

OM-441 1 Page 27 Ref. 203 096 7-2. V ariable Frequency (Hz) Generator Power Receptacle RC3  Do not operate equipment re- quiring a constant frequency from variable frequency re- ceptacle RC3. 1 120 V 20 A V ariable Frequency AC Receptacle RC3 Receptacle supplies single-phase power continuously . Frequency (Hz) of generator power output changes w[...]

OM-441 1 Page 28 7-3. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) plug1 1 1/03 − 120 813-D The plug can be wired for a 240 V , 2-wire load or a 120/240V , 3-wire load. See circuit diagram. 1 Plug Wired for 120/240 V , 3-Wire Load When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 [...]

OM-441 1 Page 29 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e Engine Manual and Maintenance Label for impor- tant start-up, service, and storage information. Service more often if used in severe conditions. * T o be done by Factory Authorized Service Age[...]

OM-441 1 Page 30 8-2. Maintenance Label Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE  Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. 8-3. Servicing Optional Spark Arrestor 1/4 in 80[...]

OM-441 1 Page 31 8-4. Servicing Air Cleaner aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759  Stop engine.  Do not run engine without air cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into wrapper . Squeeze o[...]

OM-441 1 Page 32 8-5. Changing Engine Oil, Oil Filter , And Fuel Filter 803 127 / S-0842  Stop engine and let cool. 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter accord- ing to engine manual.  Close valve and valve cap before adding oil and run- ning engine. Fill crankcase with new oil to full mark on dipstick (see Section 8-2)[...]

OM-441 1 Page 33  Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote receptacle RC4. If CB5 opens, 2 4 volt ac output to RC4 stops. 2 Fuse F1 (See Parts List) 3 Fuse F2 (See Parts [...]

OM-441 1 Page 34 8-7. T roubleshooting A. Welding T rouble Remedy No weld output. Check control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote control to Remote receptacle RC4 (see Sections 5-8 an[...]

OM-441 1 Page 35 T rouble Remedy Lack of high frequency; difficulty in establishing Gas Tungsten Arc W eld- ing arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.). Check cables and torch for cracked or[...]

OM-441 1 Page 36 D. Engine T rouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 8-6). Check battery voltage. Check battery connections and tighten if necessary . Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine does not start. Check fuel level ([...]

OM-441 1 Page 37 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Star t Y our Pr ofessional W elding Career Now![...]

OM-441 1 Page 38 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For W elding Generator[...]

OM-441 1 Page 39 21 1 395-C[...]

OM-441 1 Page 40 SECTION 10 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 10-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong [...]

OM-441 1 Page 41 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electr[...]

OM-441 1 Page 42 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 28[...]

OM-441 1 Page 43 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in[...]

OM-441 1 Page 44 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting [...]

OM-441 1 Page 45 10-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.  Customer -supplied equipment is re- qui[...]

OM-441 1 Page 46 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 [...]

OM-441 1 Page 47 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

OM-441 1 Page 48 SECTION 1 1 − P ARTS LIST 16 19 Fig.1 1-2 − 35 30 18 37 38 36 3 2 40 1 4 17 7 8 − Fig.1 1-3 7 9 11 27 25 20 21 23 24 22 10 26 6 5 12 14 13 15 28 29 33 32 31 34 41 − Fig.1 1-4 803 340 Figure 1 1-1. Main Assembly[...]

OM-441 1 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 181881 Grommet, Plastic Neck Filler Fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 166608 Cap, T ank Screw − on W/V ent 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-441 1 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 37 182367 Panel, Side Rh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ♦ 185352 Panel, Side Rh Stainless Steel 1 . . . . . . . . . . . . . . . . .[...]

OM-441 1 Page 51  Hardware is common and not available unless listed. 803 341 1 2 3 5 4 6 7 9 8 10 12 11 13 14 15 16 17 18 20 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Figure 1 1-2. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Figure 1 1-1 Item 35) Quantity 1 Nameplate[...]

OM-441 1 Page 52 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Continued) Quantity 206886 Harness, W rg Ignition (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 S4 01 1609 Switch, Tgl Spdt 15a 125vac On − none − on Spd T erm Chr [...]

OM-441 1 Page 53  Hardware is common and not available unless listed. 803 343 1 2 4 5 7 8 10 11 13 14 15 16 17 4 3 6 9 12 Figure 1 1-3. Bracket w/Components Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Bracket w/Components (Figure 1 1-1 Item 8) Quantity 1 PC1 212705 Circuit Card Assy , Power 1 . . . . . . . . . . . . . . . . . . . . . [...]

OM-441 1 Page 54 Description Part No. Item No. Figure 11-4 . Generator (Figure 1 1-1 Item 41) Quantity Dia. Mkgs. 1 ST A TOR +206890 Stator , Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 182092 Label, W arning Moving Parts Can Cause Serious Etc 3 . . . . . . . . . . . . . [...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 3/04 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mf g. Co. An Illinois T ool Wor ks Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headqua rters − Unite[...]