Miller PRO 300 CAT Owner's Manual

PRO 300(CAT-Powered)OM-4422 215 177EJuly 2004Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick

OM-4422 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4422 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4422 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4422 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not

OM-4422 Page 103/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Donot

OM-4422 Page 111 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel. Fire can result fromweldi

OM-4422 Page 123/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. Read

OM-4422 Page 133-2. Manufacturer’s Rating LabelRef. 216 347-B

OM-4422 Page 143-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSta

OM-4422 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4422 Page 164-3. Volt-Ampere Curves217 517 / 217 516 / 217 518The volt-ampere curves show theminimum and maximum voltageand amperage output capabil

OM-4422 Page 174-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.217 509IDLEDC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL/HR

OM-4422 Page 184-6. AC Generator Power Curve217 519The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4422 Page 19SECTION 5 − INSTALLATIONinstall3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transpo

OM-4422 Page 205-2. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on bas

OM-4422 Page 215-3. Installing Exhaust Pipe1/2 inTools Needed:803 582 / Ref. 214 778-B Stop engine and let cool. Point exhaust pipe in desired di-re

OM-4422 Page 225-4. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber

OM-4422 Page 235-5. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:803 563 / Ref. 214 778-B / S-0756-C Close door after

OM-4422 Page 245-6. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4422 Page 255-7. Connecting To Weld Output TerminalsTools Needed:3/4 in12 Stop engine.1 Work (−) Weld Output Terminal2 CV (Wire) Weld Output Termi

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-4422 Page 265-9. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbreaker CB8.24 VOLT

OM-4422 Page 27NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your ProfessionalWelding

OM-4422 Page 28SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)214 778-B / 803 5631 25467 89103

OM-4422 Page 296-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting aid f

OM-4422 Page 306-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswi

OM-4422 Page 316-4. Lift-Arc Start ProcedureLift-Arc  TIGWith Lift-Arc TIG selected, startarc as follows:1 TIG Electrode2 WorkpieceTurn gas on. Tou

OM-4422 Page 326-5. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-9). When a remote

OM-4422 Page 33SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Receptacles214 778-B1 120 V 20 A AC (shown) Receptacle RC5 and/or G

OM-4422 Page 34SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the

OM-4422 Page 35Every 500 hReplace Secondary(Canister) Fuel Filter.See Section 8-9.Replace primary (in-line)fuel filter. See Section8-9.Repair OrReplac

TABLE OF CONTENTSSECTION 8 − MAINTENANCE & TROUBLESHOOTING 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4422 Page 368-3. Maintenance Label

OM-4422 Page 378-4. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using ad

OM-4422 Page 388-5. Inspecting And Cleaning Optional Spark Arrestor Muffler803 582 / Ref. 214 778-B Stop engine and let cool.1 Spark Arrestor Muffler

OM-4422 Page 398-7. Adjusting Engine Speed On Standard Models803 563312RPM (Hz)Engine Speed(No Load)Weld/Power1850 (61.7)Maximum Stop engine and let

OM-4422 Page 408-8. Adjusting Engine Speed On Models With Automatic Idle (Optional)803 5631880 rpm max(62.6 Hz)1250 rpm(41.6 Hz)Engine Speed(No Load)A

OM-4422 Page 418-9. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434 / 803 563 Stop engine and let cool. After servicing, start enginean

OM-4422 Page 428-10. Overload Protection803 562 / 803 56615 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious pro

OM-4422 Page 438-11. Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions. When a help code

OM-4422 Page 448-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection 8-11).NoteA. Weld

OM-4422 Page 45Trouble RemedyNo generator power or weld output. Disconnect equipment from generator power receptacles during start-up.Check fuse F1, a

OM-4422 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

OM-4422 Page 46Trouble RemedyBattery discharges between uses. Turn Engine Control switch off when unit is not running.Clean top of battery with baking

OM-4422 Page 47NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-4422 Page 48SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

OM-4422 Page 49219 228−B

OM-4422 Page 50SECTION 10 − RUN-IN PROCEDURErun_in1 8/0110-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4422 Page 5110-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4422 Page 5210-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4422 Page 53SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4422 Page 5411-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4422 Page 5511-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4422 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4422 Page 5611-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4422 Page 5711-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4422 Page 5811-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4422 Page 5911-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4422 Page 60SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.1−Fig.

OM-4422 Page 61803 683-B567577767879808174−Fig.15−4737271706968675354555658576059626163666564343536373839304142464748494350515245444331323330292827262

OM-4422 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 Figure 12-3 Control Panel 1. . . . . . . . . . . . . . . . . .

OM-4422 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity51 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 Duro

OM-4422 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity85 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp &

OM-4422 Page 65 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 684-A12345637367891011121

OM-4422 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4422 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity10 214543 Enclosure, Circuit Card Assy 1

OM-4422 Page 67 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-B1234567891013121114F

OM-4422 Page 68803 686-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.23145678910111213141

OM-4422 Page 69803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure 12

OM-4422 Page 70 Some wiring harness components (switches, relays, circuit breakers) are also referencedelsewhere in this parts list. Purchase componen

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4422 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4422 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez