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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS

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READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance

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1-6. California Proposition 65 Warnings

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1-7. Principal Safety Standards

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1-8. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Signification des symboles

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2-2. Dangers relatifs au soudage à l’arc

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

. . . . . .

2-6. Principales normes de sécurité

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2-7. Information sur les champs électromagnétiques

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SECTION 3

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DEFINITIONS

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3-1. Symbol Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Description

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4-2. Weld, Power, And Engine Specifications

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4-3. Dimensions, Weights, and Operating Angles

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4-4. Fuel Consumption While Welding And Using Generator Power

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4-5. Generator Power Curve

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4-6. Duty Cycle

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4-7. Stick And MIG Mode Volt-Ampere Curves

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4-8. DC TIG Mode Volt-Ampere Curves

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SECTION 5

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INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator

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5-2. Engine Prestart Checks

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5-3. Activating The Dry Charge Battery (If Applicable)

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5-4. Connecting The Battery

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5-5. Installing Exhaust Pipe

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5-6. Connecting To Weld Output Terminals

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5-7. Selecting Weld Cable Sizes*

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5-8. Remote Receptacle Information

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5-9. Adjusting Wire (MIG) Weld Puddle Consistency

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SECTION 6

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OPERATING WELDING GENERATOR

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6-1. Front Panel Controls

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6-2. Description Of Front Panel Controls

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6-3. Process Switch

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6-4. Remote Amperage/Voltage Control

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SECTION 7

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OPERATING AUXILIARY EQUIPMENT

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7-1. 60 Hz Generator Power Receptacles And Circuit Breakers

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7-2. Variable Frequency (Hz) Generator Power Receptacle RC3

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7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

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Содержание Legend 301 G

Страница 1: ...IG GTAW Welding Stick SMAW Welding Engine Driven Welding Generator OM 4411 207 283E May 2004 Miller Legend 301 G Visit our website at www MillerWelds com MIG GMAW Welding Flux Cored FCAW Welding With...

Страница 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Страница 3: ...pecifications 10 4 3 Dimensions Weights and Operating Angles 10 4 4 Fuel Consumption While Welding And Using Generator Power 11 4 5 Generator Power Curve 11 4 6 Duty Cycle 12 4 7 Stick And MIG Mode Vo...

Страница 4: ...30 8 3 Servicing Optional Spark Arrestor 30 8 4 Servicing Air Cleaner 31 8 5 Changing Engine Oil Oil Filter And Fuel Filter 32 8 6 Overload Protection 33 8 7 Troubleshooting 34 SECTION 9 ELECTRICAL DI...

Страница 5: ...d plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for dama...

Страница 6: ...cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damage...

Страница 7: ...METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot co...

Страница 8: ...ng Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec...

Страница 9: ...lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform...

Страница 10: ...revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandations dans OSHA...

Страница 11: ...le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi op rer comme...

Страница 12: ...s que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 2 6 Principales normes de s curit Safety in Welding C...

Страница 13: ...d Operator s Manual A Amperes V Volts MIG GMAW Wire Stick SMAW TIG GTAW Circuit Breaker Positive Negative Alternating Current AC Output Time h Hours s Seconds Protective Earth Ground Do not switch whi...

Страница 14: ...280 A 25 V 100 Duty Cycle 72 20 300 A 10 33 V 5 5 kVA kW Peak 5 kVA kW Continuous 42 21 A 120 240 V AC 60 Hz Single Phase at 1800 rpm 10 gal 38 L Kohler CH 20 Air Cooled Two Cylinder Four Cycle CV DC...

Страница 15: ...UTY CYCLE U S GAL HR 1 98 0 95 2 84 3 78 5 67 4 73 6 62 7 57 LITERS HR 0 00 3600 RPM Weld Generator at 5 kW Generator at 4 kW Generator at 2 kW Generator at 1 kW Generator at 3 kW Idle At 1800 RPM 207...

Страница 16: ...y cycle can damage unit and void warranty 100 Duty Cycle at 280 Amperes DC CC Continuous Welding 4 6 Duty Cycle Ref 207 925 0 10 20 30 40 50 60 100 70 80 90 150 175 200 225 250 275 300 DUTY CYCLE WELD...

Страница 17: ...enerator Curves of other settings fall between the curves shown A CC DC Stick Mode B CV DC MIG Mode 4 7 Stick And MIG Mode Volt Ampere Curves 3600 RPM 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250...

Страница 18: ...pabilities of the welding generator Curves of other settings fall between the curves shown 4 8 DC TIG Mode Volt Ampere Curves 0 5 10 15 20 25 30 35 40 45 50 0 50 100 150 200 250 300 350 DC AMPERES DC...

Страница 19: ...unting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Co...

Страница 20: ...ften and do not use the oil pressure shutdown system to monitor oil level Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Always leave filler neck em...

Страница 21: ...Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery char...

Страница 22: ...ded 5 5 Installing Exhaust Pipe 801 681 Ref 211 909 Stop engine and let cool Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from ex...

Страница 23: ...ersized or poorly spliced cables Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 9...

Страница 24: ...OLTS AC I 115 volts ac Protected by fuse F2 D M G E F J Not used A V C Output to remote control 0 to 10 volts dc output to remote control in Stick and TIG modes 10 volts dc output to remote control in...

Страница 25: ...steel Lead 27 provides wettest weld puddle for stainless steel Lead 29 is connected to the Wire CV weld output terminal at the factory Disconnect lead 29 from the Wire CV weld output terminal For wett...

Страница 26: ...OM 4411 Page 22 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls 2 1 4 3 Ref 211 909 7 5 6...

Страница 27: ...ed by weld load and posi tion of Speed Control switch see item 7 and table below Generator power is available at recep tacles RC1 and RC2 only at 1800 rpm If generator is not locked at 1800 rpm engine...

Страница 28: ...and gouging When switch is in a Stick position the dig circuit provides additional amperage dur ing low voltage short arc length condi tions to prevent sticking electrodes The dig circuit is disabled...

Страница 29: ...to the remote receptacle makes closure be tween pins A and B example trigger pull on MIG gun Process Stick Using Remote On Off In Example 2 Max 180 A CC DC Min 40 A CC DC Max 180 A DC Min 40 A DC Set...

Страница 30: ...s ac 3 Circuit Breaker CB1 CB1 protects receptacles RC1 and RC2 from overload If CB1 opens the receptacles do not work Place switch in On position to reset breaker 4 Circuit Breaker CB3 CB3 protects R...

Страница 31: ...gle phase power continuously Frequency Hz of generator power output changes with engine speed Total output avail able is 2 4 kVA kW 2 Circuit Breaker CB4 CB4 protects the receptacle from overload If C...

Страница 32: ...ach duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Termin...

Страница 33: ...am element See Section 8 4 Every 50 h Clean and tighten weld terminals Every 100 h Change oil See Section 8 5 and maintenance label Clean cooling system See engine manual Service air filter element Se...

Страница 34: ...er s manual if the unit will not be used for an extended period NOTE Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or miss...

Страница 35: ...ne Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenl...

Страница 36: ...to engine manual Close valve and valve cap before adding oil and run ning engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 3 Fuel Filter 4 Fuel Line Replace line if cracked...

Страница 37: ...ocated on power board PC7 F1 protects the exciter stator from overload If F1 opens weld and generator power output stops Fuse F2 is located behind front panel F2 protects the 115 volt ac output to Rem...

Страница 38: ...see Section 8 4 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 See engine manual High weld output Check control settings Check for obstructed movement of...

Страница 39: ...eck fuse F1 on circuit board PC7 and replace if necessary see Section 8 6 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 PC2 and PC7 Low power output at 60 Hz ac...

Страница 40: ...Control switch in Off position when unit is not running Clean top of battery with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Repla...

Страница 41: ...OM 4411 Page 37 Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Страница 42: ...OM 4411 Page 38 SECTION 9 ELECTRICAL DIAGRAM Figure 9 1 Circuit Diagram For Welding Generator...

Страница 43: ...OM 4411 Page 39 211 395 C...

Страница 44: ...enerator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Groun...

Страница 45: ...istive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 10 8 3 Rating Data Rating shows volt...

Страница 46: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Страница 47: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Страница 48: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Страница 49: ...f required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perm...

Страница 50: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Страница 51: ...tes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 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 MATERIAL THICKNES...

Страница 52: ...1 Page 48 SECTION 11 PARTS LIST 16 19 Fig 11 2 35 30 18 37 38 36 3 2 40 1 4 17 7 8 Fig 11 3 7 9 11 27 25 20 21 23 24 22 10 26 6 5 12 14 13 15 28 29 33 32 31 34 41 Fig 11 4 803 340 Figure 11 1 Main Ass...

Страница 53: ...using Plug Skts Service Kit 1 F6 021718 Fuse Mintr Gl 30 Amp 32 Volt 1 180096 Tune up Filter Kit Kohler Includes 1 067272 Air Filter Element Kohler 1 066698 Oil Filter Kohler 1 215985 Filter Clamps Fu...

Страница 54: ...t 2row Plug Cable Lkg 1 206534 Harness Wrg Interconnecting Includes 1 RC9 136924 Conn Rect Comm 093 2p S 1row Rcpt Cable Lkg 1 PLG25 113752 Conn Rect Mini 045 10skt 2row Plug Cable Lkg 1 RC7 092670 Co...

Страница 55: ...273 Circuit Card Assy Control 1 206794 Shield Pcb Protective Anti Static 4 813x12 750 1 209618 Harness Remote Control 14pin Includes 1 5 209617 Holder Fuse W 10A Fuse Includes 1 F2 085874 Fuse Mintr C...

Страница 56: ...X 2 12 Rect 1 21 134201 Stand off Support Pc Card 312 375w Post lock 43 6 22 CC CV 039047 Terminal Pwr Output Red 2 GRD 197203 Grounding Stud Assy Brass Includes 1 23 083030 Stud Brs 250 20 X 1 750 W...

Страница 57: ...6 32 X 687 Lg 250 Hex Al Fem 10 5 004214 Bushing Snap in Nyl 1 625 Id X 2 000 Mtg Hole 1 6 200263 Label Warning Electric Shock Hazard 2 7 206901 Bracket Mtg Relay 1 8 CR2 113247 Relay Encl 12vdc Dpdt...

Страница 58: ...Cable Lkg 1 RC22 136924 Conn Rect Comm 093 2p S 1row Rcpt Cable Lkg 1 10 010910 Washer Flat 406idx0 812odx 065t Stl Pld Ansi 375 4 11 010909 Nut 375 16 56hex 46h Stl Pld Elastic Stop Nut 4 12 218049...

Страница 59: ...ma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as co...

Страница 60: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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