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Miller Electric 301 G Owner's Manual

Miller electric owner's manual welding generator miller legend 301 g.

 
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www.MillerWelds.com
Miller Legend 301 G
OM-4411
207 283E
May 2004
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) Welding-
With Voltage Sensing Feeder
Description
Engine Driven Welding Generator
R
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Summary of Contents

  • Page 1

    Miller Legend 301 G Visit our website at www.MillerWelds.com OM-4411 207 283E May 2004 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding & Flux Cored (FCAW) Welding- With Voltage Sensing Feeder Description Engine Driven Welding Generator...

  • Page 2

    ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance ..............8-2.

  • Page 5: Symbol Usage, Arc Welding Hazards

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. Welding 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.

  • Page 7: Compressed Air Hazards, Additional Symbols For Installation, Operation, And Maintenance

    STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

  • Page 8: California Proposition 65 Warnings, Principal Safety Standards, Emf Information

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D 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. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 9: Signification Des Symboles

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Y Avertissement: 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 par des symboles adjacents aux directives.

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

  • Page 11

    L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. D Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. D Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.

  • Page 12

    LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. D 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. D Ne pas brancher de moteur de 50 ou de 60 Hz à...

  • Page 13: Symbol Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Start Engine Engine Oil Engine MIG (GMAW), Wire Positive Time Do not switch while welding Wire Feed Notes Fast Fast/Slow (Run, Weld/Power) (Run/Idle) Panel/Local Temperature Check Valve Engine Choke Clearance Read Operator’s Amperes Manual Stick (SMAW)

  • Page 14: Description, Weld, Power, And Engine Specifications, Dimensions, Weights, And Operating Angles

    SECTION 4 − SPECIFICATIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out- put for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator power.

  • Page 15: Fuel Consumption While Welding And Using Generator Power, Generator Power Curve

    4-4. Fuel Consumption While Welding And Using Generator Power 7.57 2.00 6.62 1.75 5.67 1.50 4.73 1.25 3.78 1.00 2.84 0.75 Idle (At 1800 RPM) 1.98 0.50 Generator 0.95 0.25 at 1 kW 0.00 0.00 4-5. Generator Power Curve 3600 RPM Weld 3000 RPM Weld Generator at 3 kW...

  • Page 16: Duty Cycle

    4-6. Duty Cycle 100% Duty Cycle at 280 Amperes DC/CC Notes OM-4411 Page 12 Continuous Welding % DUTY CYCLE Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit warranty.

  • Page 17: Stick And Mig Mode Volt-ampere Curves

    4-7. Stick And MIG Mode Volt-Ampere Curves A. CC/DC Stick Mode B. CV/DC MIG Mode 3000 RPM 3600 RPM DC AMPERES 3600 RPM 3000 RPM DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 18: Dc Tig Mode Volt-ampere Curves

    4-8. DC TIG Mode Volt-Ampere Curves Notes OM-4411 Page 14 DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. 204 930 Work like a Pro! Pros weld and cut safely.

  • Page 19: Installing Welding Generator

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Y Do not lift unit from end. Location Mounting Inadequate support. Y Do not use flexible mounts. Grounding GND/PE Airflow Clearance 18 in (460 mm) 18 in (460 mm) Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 20: Engine Prestart Checks

    5-2. Engine Prestart Checks Full Gasoline OM-4411 Page 16 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.

  • Page 21: Activating The Dry Charge Battery (if Applicable)

    5-3. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes − Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 22: Connecting The Battery, Installing Exhaust Pipe

    5-4. Connecting The Battery Tools Needed: 3/8, 1/2 in 5-5. Installing Exhaust Pipe Tools Needed: 1/2 in OM-4411 Page 18 Y Connect negative (−) cable last. − Ref. 800 394-C / Ref. 211 909 / Ref. S-0756-D Y Stop engine and let cool. Y Engine backfire can cause se- vere burns or other injuries.

  • Page 23: Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

    5-6. Connecting To Weld Output Terminals 5-7. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cable overheats, 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.

  • Page 24: Remote Receptacle Information

    5-8. Remote Receptacle Information NOTE Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to the remote receptacle is running. C L N Notes OM-4411 Page 20 Socket* 24 volts ac. Protected by circuit breaker CB5. 24 VOLTS AC Not used.

  • Page 25: Adjusting Wire (mig) Weld Puddle Consistency

    5-9. Adjusting Wire (MIG) Weld Puddle Consistency Tools Needed: 3/8, 7/16 in Y Stop engine and let cool. Stabilizer DC-Z is factory connected to suit most Wire (MIG) welding applica- tions. To change Wire (MIG) weld puddle con- sistency, proceed as follows: Remove cover and right side panel.

  • Page 26: Front Panel Controls

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls Ref. 211 909 OM-4411 Page 22...

  • Page 27: Description Of Front Panel Controls

    6-2. Description Of Front Panel Controls Process Switch See Section 6-3 for Process switch informa- tion. Voltage/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- tacle RC4 (see Sections 5-8 and 6-4).

  • Page 28: Process Switch

    6-3. Process Switch Switch Setting Switch Setting Electrode Hot − Wire Electrode Hot − Stick Air Carbon Arc (CAC-A) Cutting And Gouging Electrode Hot − Scratch Start TIG OM-4411 Page 24 Process Switch Settings Process Process MIG (GMAW) Stick (SMAW), Scratch Start TIG (GTAW) Process Switch Y Weld output terminals are ener-...

  • Page 29: Remote Amperage/voltage Control

    6-4. Remote Amperage/Voltage Control Example: Combination Remote Amperage Control (Stick) Set V/A Adjust Switch Max (180 A DC) Min (40 A DC) Set Process Adjust Remote Control (Stick Welding Only) This unit does not have remote con- tactor control. Output is always on. Remote Receptacle RC4 Connect optional remote control to RC4 (see Section 5-8).

  • Page 30: Hz Generator Power Receptacles And Circuit Breakers

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Circuit Breakers Controlling Engine Speed And Weld/Generator Power Output Engine Controls Engine Speed Either Run/Idle 1800 rpm position. (Power Speed) Continuous No Load: 2400 rpm (Idle Speed) Load: 3600 rpm (Weld Speed) No Load: 1800 rpm...

  • Page 31

    7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 Notes Y Do not operate equipment re- quiring a constant frequency from variable frequency re- ceptacle RC3. 120 V 20 A Variable Frequency AC Receptacle RC3 Receptacle supplies single-phase power continuously. Frequency (Hz) of generator power output changes with engine speed.

  • Page 32: Wiring Instructions For Optional 240 Volt, Single-phase Plug (nema 14-50p)

    7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) Current Available in Amperes 240 V Each 120 V Duplex Receptacle* Receptacle V x A = Watts *One 240 V load or two 120 V loads. OM-4411 Page 28 120V 120V 240V...

  • Page 33: Routine Maintenance

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Check fluid levels. See Section 5-2. 20 h Check and clean spark arrestor screen. See Section 8-3. Clean and tighten weld terminals. Change oil. See Section 8-5 and maintenance label. Clean cooling system. See engine manual.

  • Page 34: Maintenance Label, Servicing Optional Spark Arrestor

    8-2. Maintenance Label NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 8-3. Servicing Optional Spark Arrestor Tools Needed: 1/4 in OM-4411 Page 30 Y Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen.

  • Page 35: Servicing Air Cleaner

    8-4. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.

  • Page 36: Changing Engine Oil, Oil Filter, And Fuel Filter

    8-5. Changing Engine Oil, Oil Filter, And Fuel Filter Full Tools Needed: OM-4411 Page 32 Y Stop engine and let cool. Oil Drain Valve 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.

  • Page 37: Overload Protection

    8-6. Overload Protection Located behind front panel. Y Stop engine. Tools Needed: When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service 3/8 in Agent. Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote receptacle RC4.

  • Page 38: Troubleshooting

    8-7. Troubleshooting A. Welding Trouble 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 and 6-1). Check and secure connections to Remote receptacle RC4 (see Sections 5-8).

  • Page 39

    Trouble Lack of high frequency; difficulty in Use proper size tungsten for welding amperage. establishing Gas Tungsten Arc Weld- ing arc. 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 deteriorated insulation or bad connections.

  • Page 40

    D. Engine Trouble 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.

  • Page 41

    Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org OM-4411 Page 37...

  • Page 42

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For Welding Generator OM-4411 Page 38...

  • Page 43

    211 395-C OM-4411 Page 39...

  • Page 44

    SECTION 10 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 45

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.

  • Page 46

    10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.

  • Page 47

    10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...

  • Page 48

    10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...

  • Page 49

    10-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...

  • Page 50

    10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 51

    Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)

  • Page 52

    SECTION 11 − PARTS LIST 803 340 Figure 11-1. Main Assembly OM-4411 Page 48...

  • Page 53

    Item Dia. Part Mkgs....181881 ....166608 .

  • Page 54

    Item Dia. Part Mkgs....182367 ....185352 ..

  • Page 55

    Hardware is common and not available unless listed. Item Dia. Part Mkgs....... .

  • Page 56

    Item Dia. Part Mkgs..... 206886 ... . . 011609 ..

  • Page 57

    Item Dia. Part Mkgs... . 212705 ... 203130 ... . . 027660 .

  • Page 58

    Item Dia. Part Mkgs..STATOR +206890 ....182092 ..ROTOR . . . 207126 ..

  • Page 59

    Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 60

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2003 Miller Electric Mfg. Co. 1/03 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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