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Miller PRO 300 User Manual

Miller PRO 300
76 pages
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PRO 300
(CAT-Powered)
OM-4422 215 177E
July 2004
Visit our website at
www.MillerWelds.com
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW) Welding
Engine Driven Welding Generator
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Table of Contents

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Miller PRO 300 Specifications

General IconGeneral
Open-Circuit Voltage (OCV)80 VDC
Weight375 lb (170 kg)
Output Current Range5 - 400 A
Rated Output300 A at 32 VDC, 60% Duty Cycle
Welding Amperage Range5 - 400 A
DimensionsH: 36 in (914 mm) W: 25 in (635 mm) L: 40 in (1016 mm)
ProcessesMIG (GMAW), Stick (SMAW), TIG (GTAW), Flux-Cored (FCAW)

Summary

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

Understanding Safety Symbols and Hazards

Explains safety symbols, arc welding, engine, and moving parts hazards.

Specific Hazard Warnings

Details burns from steam/coolant/battery acid, engine heat/exhaust, compressed air, and hot metal risks.

Installation, Operation, and Maintenance Safety

Safety for unit installation, operation, and maintenance, including static and trailer tilting.

Regulatory and Reference Information

California Proposition 65 warnings, safety standards, and EMF information.

SECTION 3 – DEFINITIONS

3-1. Warning Label Definitions

Explanations of various warning labels found on the equipment.

3-3. Symbols And Definitions

Definitions and meanings of symbols used in the manual.

SECTION 4 – SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Detailed specifications for welding output, power, and engine.

4-2. Dimensions, Weights, And Operating Angles

Physical dimensions, weight, and safe operating angles.

4-3. Volt-Ampere Curves

Graphs showing voltage and amperage output capabilities.

4-5. Duty Cycle And Overheating

Information on duty cycle limits and overheating prevention.

SECTION 5 – INSTALLATION

5-1. Installing Welding Generator

Procedures for safely installing the welding generator.

5-2. Mounting Welding Generator

Instructions for securely mounting the welding generator.

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

Procedure for activating the dry charge battery.

5-5. Connecting The Battery

Instructions for correctly connecting the battery.

5-6. Engine Prestart Checks

Essential checks before starting the engine.

5-8. Selecting Weld Cable Sizes*

Guide for choosing appropriate weld cable sizes.

SECTION 6 – OPERATING WELDING GENERATOR

6-1. Front Panel Controls

Overview of the controls located on the front panel of the unit.

6-2. Description Of Front Panel Controls

Detailed explanation of each front panel control's function.

6-3. Process/Contactor Switch On CC/CV Models

How to use the Process/Contactor switch for different welding modes.

6-5. Remote Voltage/Amperage Control

How to use remote controls for voltage and amperage adjustment.

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Receptacles

Information on operating and using the auxiliary power receptacles.

SECTION 8 – MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Schedule and tasks for regular maintenance of the unit.

8-4. Servicing Air Cleaner

Procedures for cleaning and servicing the air cleaner.

8-6. Servicing Engine Cooling System

Instructions for servicing the engine's cooling system.

8-9. Servicing Fuel And Lubrication Systems

Maintenance procedures for fuel and lubrication systems.

8-10. Overload Protection

Explanation of overload protection devices like circuit breakers and fuses.

8-12. Troubleshooting

General troubleshooting guide for welding and generator power issues.

C. Engine (Troubleshooting)

Troubleshooting specific engine-related problems.

SECTION 9 – ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

Detailed electrical schematic of the welding generator.

SECTION 10 – RUN-IN PROCEDURE

10-1. Wetstacking

Explanation of wetstacking and its causes during engine run-in.

10-2. Run-In Procedure Using Load Bank

Step-by-step procedure for run-in using a load bank.

10-3. Run-In Procedure Using Resistance Grid

Step-by-step procedure for run-in using a resistance grid.

SECTION 11 – GENERATOR POWER GUIDELINES

11-2. Grounding Generator To Truck Or Trailer Frame

Instructions for grounding the generator frame to vehicle frames.

11-4. How Much Power Does Equipment Require?

Calculating power requirements for connected equipment.

11-8. Power Required To Start Motor

Calculating starting power requirements for motors.

11-9. How Much Power Can Generator Supply?

Guidelines on managing generator load and supply capacity.

SECTION 12 – PARTS LIST

Figure 12-1. Main Assembly

Exploded view and parts list for the main assembly.

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