Manuals / Miller Electric / Power Tools / Welding System

Miller Electric 301 G manual Owner’s Record, For Service, Miller Electric Mfg. Co

Models: 301 G

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Owner’s Record

Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number

Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:	Welding Supplies and Consumables
	Options and Accessories
	Personal Safety Equipment
	Service and Repair
	Replacement Parts
	Training (Schools, Videos, Books)
	Technical Manuals (Servicing Information
	and Parts)
	Circuit Diagrams
	Welding Process Handbooks

Contact the Delivering Carrier to:	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.
PRINTED IN USA	 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

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

www.MillerWelds.com

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Miller Electric 301 G manual Owner’s Record, For Service, Please complete and retain with your personal records

Contents

Miller LegendR 301 G OM-4411207 283EProcesses DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONTABLE OF CONTENTS 8-2. Maintenance Label 8-3. Servicing Optional Spark Arrestor8-4. Servicing Air Cleaner 8-6. Overload Protection 8-7. Troubleshooting1-1. Symbol Usage 1-2. Arc Welding HazardsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Means “Note” not safety related1-3. Engine Hazards BATTERY EXPLOSION can BLINDWELDING can cause fire or explosion FLYING METAL can injure eyes1-5. Additional Symbols For Installation, Operation, And Maintenance 1-4. Compressed Air HazardsSTEAM AND HOT COOLANT can burn ENGINE EXHAUST GASES can kill1-7. Principal Safety Standards 1-6. California Proposition 65 Warnings1-8. EMF Information READ INSTRUCTIONS2-1. Signification des symboles SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION2-2. Dangers relatifs au soudage à l’arc UN CHOC ÉLECTRIQUE peut tuer2-3. Dangers existant en relation avec le moteur LE SOUDAGE peut provoquer un in- cendie ou une explosionDES PARTICULES VOLANTES peuvent blesser les yeux DES PIÈCES CHAUDES peuvent provoquer des brûlures graves2-4. Dangers liés à l’air comprimé L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLEDES ORGANES MOBILES peuvent provoquer des blessures LA CHALEUR DU MOTEUR peut pro- voquer un incendie2-6. Principales normes de sécurité 2-7. Information sur les champs électromagnétiquesLE SURCHAUFFEMENT peut endom- mager le moteur électrique LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures3-1. Symbol Definitions SECTION 3 − DEFINITIONSWork like a Pro SECTION 4 − SPECIFICATIONS 4-2. Weld, Power, And Engine Specifications4-3. Dimensions, Weights, and Operating Angles 4-1. Description4-4. Fuel Consumption While Welding And Using Generator Power 4-5. Generator Power Curve4-6. Duty Cycle Y Exceeding duty cycle can damage unit and void warrantyWork like a Pro Continuous Welding4-7. Stick And MIG Mode Volt-Ampere Curves A. CC/DC Stick ModeB. CV/DC MIG Mode 4-8. DC TIG Mode Volt-Ampere Curves Work like a ProSECTION 5 − INSTALLATION 5-1. Installing Welding GeneratorMovement Y Do not lift unit from end Location5-2. Engine Prestart Checks Follow run-in procedure in engine manualTo improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather5-3. Activating The Dry Charge Battery If Applicable Y Do not overfill battery cellsWhen electrolyte is low, add Y Read and follow all instruc5-4. Connecting The Battery 5-5. Installing Exhaust PipeY Connect negative − cable last Y Stop engine and let coolConnecting To Weld Output Terminals Selecting Weld Cable Sizes5-8. Remote Receptacle Information 24 VOLTS AC115 VOLTS AC AMPERAGE5-9. Adjusting Wire MIG Weld Puddle Consistency Y Stop engine and let coolFor wetter weld puddle for mild steel For wettest weld puddle for stainless steelSECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls6-2. Description Of Front Panel Controls Generator power is available at recepControlling Engine Speed And Weld/Generator Power Output Speed Control Switch In Weld Engine Control Switch in 3600/2400 RPM6-3. Process Switch Process Switch SettingsSwitch Setting Process6-4. Remote Amperage/Voltage Control tween pins A and B exampleEngine runs at weld speed when receptacle makes closure be7-1. 60 Hz Generator Power Receptacles And Circuit Breakers SECTION 7 − OPERATING AUXILIARY EQUIPMENTControlling Engine Speed And Weld/Generator Power Output Generator power is available at7-2. Variable Frequency Hz Generator Power Receptacle RC3 Work like a Proceptacle RC3 1 120 V 20 A Variable FrequencyEach 120 V Duplex ReceptacleCurrent Available in Amperes ReceptacleSECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine MaintenanceEvery 8 h 20 h8-2. Maintenance Label 8-3. Servicing Optional Spark ArrestorY Stop engine and let cool 803 127 / Ref. 2118-4. Servicing Air Cleaner Y Do not run engine without air cleaner or with dirty elementY Stop engine 8-5. Changing Engine Oil, Oil Filter, And Fuel Filter Y Stop engine and let coolY Close valve and valve cap before adding oil and run- ning engine Y Stop engine, tighten connec- tions as necessary, and wipe up fuel8-6. Overload Protection When a circuit breaker or fuseY Stop engine 8-7. Troubleshooting A. WeldingTrouble RemedyB. 60 Hz Generator Power Receptacles RC1 And RC2 C. Variable Frequency Generator Power Receptacle RC3Trouble RemedyD. Engine TroubleRemedy Start Your Professional Welding Career Now Over 80,000 trained since400 Trade Square East, Troy, Ohio SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For Welding GeneratorOM-4411 Page 211 395-CSECTION 10 − GENERATOR POWER GUIDELINES 10-1. Selecting Equipment10-2. Grounding Generator To Truck Or Trailer Frame has this symbol10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require?earth ground if supplying Use ground device as stated10-5. Approximate Power Requirements For Industrial Motors 10-6. Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating10-7. Approximate Power Requirements For Contractor Equipment ContractorRating Starting Watts10-8. Power Required To Start Motor 10-9. How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements Motor Start10-10. Typical Connections To Supply Standby Power Work like a Pro10-11. Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load WattsMATERIAL THICKNESS REFERENCE CHART 24 Gauge .025 in 22 Gauge .031 in 20 Gauge .037 in 18 Gauge .050 in 16 Gauge .063 in14 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 inFigure 11-1. Main Assembly SECTION 11 − PARTS LISTFigure 11-1. Main Assembly Grommet, Plastic Neck Filler FuelFigure 11-1. Main Assembly Continued Start Your Professional Welding Career NowOver 80,000 trained since Figure 11-2. Panel Front w/ComponentsFigure 11-2. Panel Front w/Components Figure 11-1 ItemFigure 11-2. Panel, Front w/Components Continued Figure 11-3. Bracket w/Components Figure 11-2. Bracket w/Components Figure 11-1 ItemHardware is common and not available unless listed Figure 11-4. Generator Figure 11-1 Item Figure 11-4. GeneratorStator, Generator Warranty Questions? ServiceCall 1-800-4-A-MILLER for your local Miller distributor SupportFor Service Owner’s RecordPlease complete and retain with your personal records Always provide Model Name and Serial/Style Number