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Miller Electric PRO 300 5-4. Activating The Dry Charge Battery (If Applicable), , , , 5-5. Connecting The Battery

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5-4. Activating The Dry Charge Battery (If Applicable)

!Always wear a face shield,

rubber gloves and protective

clothing when working on a

battery.

Remove battery from unit.

5 Vent Caps

6 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

7 Well

Fill each cell with electrolyte to

bottom of well (maximum).

!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.

8 Battery Charger

!Read and follow all instruc-

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.

1

Tools Needed:

2

4

30 A For 12 Minutes

5 A For 30 Minutes

OR +

−

3

drybatt1 6/05 − S-0886

5-5. Connecting The Battery

1/2 in

−

+

!Connect Negative (−) Cable Last.

Tools Needed:

803 563 / Ref. 214 778-B / S-0756-C

Close door after connecting battery.

Contents

Main PRO 300 (CAT-Powered) From Miller to You Page TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists in inverters after stop- ping engine. FUMES AND GASES can be hazardous. BUILDUP OF GAS can injure or kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. NOISE can damage hearing. 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. HOT PARTS can cause severe burns. 1-5. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERHEATING can damage motors. FLYING SPARKS can cause injury. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information SECTION 2 UTILISATION 2-1. Signification des symboles 2-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation. DES PICES CHAUDES peuvent provoquer des brlures graves. DES PIECES DE METAL ou DES SA- LETES peuvent provoquer des bles- sures dans les yeux. u s e 2-3. Dangers existant en relation avec le moteur LEXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE. LE CARBURANT MOTEUR peut prov quer un incendie ou une explosion. DES ORGANES MOBILES peuvent pr o 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. LE SURCHAUFFEMENT peut endom- mager le moteur lectrique. LES TINCELLES VOLANTES ris- quent de provoquer des blessures. DES ORGANES MOBILES peuvent provoquer des blessures. LES FILS DE SOUDAGE peuvent provoquer des blessures. LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT. 2-6. Proposition californienne 65 Avertissements 2-7. Principales normes de scurit 2-8. Information EMF SECTION 3 DEFINITIONS + 3 4 3-1. Warning Label Definitions 2 Page 3-3. Symbols And Definitions AAmperes VVolts Panel/Local Remote 3 n X Duty Cycle U0 SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications ! Output Range Rated Welding Page Page Page SECTION 5 INSTALLATION ! 5 ! ! 5-2. Mounting Welding Generator ! Page 5-4. Activating The Dry Charge Battery (If Applicable) ! + ! 5-5. Connecting The Battery 5-6. Engine Prestart Checks 5-7. Connecting To Weld Output Terminals ! 5-8. Selecting Weld Cable Sizes* ! Over 80,000 trained since 1930! Start Your Professional Welding Career Now! 5-9. Connecting To Remote 14 Receptacle RC14 24 VOLTS AC OUTPUT 24 VOLTS AC REMOTE Page Page 6-2. Description Of Front Panel Controls (See Section 6-1) 6-3. Process/Contactor Switch On CC/CV Models ! Process/Contactor Switch Settings 6-4. Lift-Arc Start Procedure 6-5. Remote Voltage/Amperage Control SECTION 7 OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles Page 8-2. Routine Maintenance ! 8-3. Caterpillar Customer Assistance 8-4. Checking Generator Brushes 8-5. Servicing Air Cleaner 8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler 8-7. Servicing Engine Cooling System 8-8. Adjusting Engine Speed On Standard Models RPM (Hz) 8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) 8-10. Servicing Fuel And Lubrication Systems ! 8-11. Overload Protection 8-12. Voltmeter/Ammeter Help Displays HL.P 22 HL.P 23 HL.P 24 HL.P 25 HL.P 20 HL.P 21 8-13. Troubleshooting A. Welding B. Standard Generator Power C. Engine Page Page Page Page SECTION 10 RUN-IN PROCEDURE 10-1. Wetstacking 10-2. Run-In Procedure Using Load Bank ! 10-3. Run-In Procedure Using Resistance Grid ! + ! SECTION 11 GENERATOR POWER GUIDELINES 11-1. Selecting Equipment ! ! 11-2. Grounding Generator To Truck Or Trailer Frame 11-3. Grounding When Supplying Building Systems ! 11-4. How Much Power Does Equipment Require? 11-5. Approximate Power Requirements For Industrial Motors 11-6. Approximate Power Requirements For Farm/Home Equipment 11-7. Approximate Power Requirements For Contractor Equipment 11-8. Power Required To Start Motor 11-9. How Much Power Can Generator Supply? 11-10. Typical Connections To Supply Standby Power ! 11-11. Selecting Extension Cord (Use Shortest Cord Possible) SECTION 12 PARTS LIST Figure 12-1. Main Assembly Page Page Page Page Page Page Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2007 (Equipment with a serial number preface of LH or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Owners Record