Miller Legend 302 Owner's Manual
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Miller Legend 302 Owner's Manual

Engine driven welding generator
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Miller Legend 302
OM-4430
217 243B
November 2004
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) Welding
With Voltage Sensing Feeder
Description
Engine Driven Welding Generator
R

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  • Page 1 OM-4430 217 243B November 2004 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding & Flux Cored (FCAW) Welding With Voltage Sensing Feeder Description Engine Driven Welding Generator Miller Legend 302 Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... . . 8-1.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/04 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or D Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the welding arc.

  • Page 7: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. BATTERY ACID can BURN SKIN and EYES. D Do not tip battery. D If possible, check coolant level when engine is cold to avoid scalding. D Replace damaged battery. D Always check coolant level at overflow tank, if pres- D Flush eyes and skin immediately with water.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. ARC WELDING can cause interference. D Use only genuine MILLER/Hobart replacement D Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as D Perform engine and air compressor (if applicable) robots.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 10/04 Y Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde !

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux.

  • Page 11: Dangers Liés À L'air Comprimé

    D Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- L’EXPLOSION DE LA BATTERIE peut nes mobiles. RENDRE AVEUGLE. D Remettre en place les panneaux ou les dispositifs de protection et fermer les portes à la fin des travaux d’entretien et avant de faire démarrer le mo- teur.

  • Page 12: Principales Normes De Sécurité

    LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compres- D Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Engine Choke Battery (Engine) Clearance Read Operator’s Engine Amperes Volts Manual MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire...

  • Page 14: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out- put for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator power.

  • Page 15: Fuel Consumption While Welding And Using Generator Power

    4-4. Fuel Consumption While Welding And Using Generator Power 7.57 2.00 6.62 1.75 5.67 1.50 4.73 1.25 3600 RPM Weld 3.78 1.00 3000 RPM Weld Generator 2.84 0.75 at 5 kW Generator at 4 kW Generator Idle (At 1800 RPM) 1.98 0.50 at 3 kW...

  • Page 16: Duty Cycle

    4-6. Duty Cycle Duty cycle is the percentage of 10 100% Duty Cycle at 280 Amperes DC/CC minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. Continuous Welding MIG/FCAW STICK % DUTY CYCLE Ref.

  • Page 17: Stick And Mig Mode Volt-Ampere Curves

    4-8. Stick And MIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the A. CC/DC Stick Mode curves shown. 3600RPM Max 3000RPM Max DC AMPERES B.

  • Page 18: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Y Always securely fasten weld- Y Do not lift unit from end. ing generator onto transport vehicle or trailer and comply with all DOT and other applica-...

  • Page 19: Engine Prestart Checks

    5-2. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in engine manual. This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts Full...

  • Page 20: Connecting Or Replacing The Battery

    5-3. Connecting Or Replacing The Battery Y Connect negative (−) cable last. − Replacing The Battery Remove end panel to replace battery. Y Connect negative (−) cable last. − − Tools Needed: 3/8, 1/2 in 803 847 / 803 849 / Ref. S-0756-D Ref 216 172−B / Ref 803 983−A OM-4430 Page 16...

  • Page 21: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Y Stop engine and let cool. Y Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe to- ward control panel. Keep away from exhaust outlet. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel.

  • Page 22: Selecting Weld Cable Sizes

    5-6. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)

  • Page 23: Adjusting Wire (Mig) Weld Puddle Consistency

    5-8. Adjusting Wire (MIG) Weld Puddle Consistency Y Stop engine and let cool. Stabilizer DC-Z is factory connected to suit most Wire (MIG) welding applications. To change Wire (MIG) weld puddle consis- tency, proceed as follows: Remove right side panels. Stabilizer DC-Z Stabilizer Tabs 1, 2, and 3 Tab 3 −...

  • Page 24: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls Ref 216 172−B OM-4430 Page 20...

  • Page 25: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Process Switch Idle 3000/1800 position to see hours before In Run/Idle 300/1800 RPM position, engine next recommended oil change. Oil change runs at 1800 rpm no weld load and 3000 rpm See Section 6-4 for Process switch informa- hours start at 100 (fresh oil) and count down under weld load.

  • Page 26: Controlling Engine Speed And Weld/Generator Output

    6-3. Controlling Engine Speed And Weld/Generator Output Set engine controls as shown to obtain the corresponding weld and generator power out- put. Generator Power Weld Output Engine Controls Output Engine Speed Either Run/Idle 1800 rpm position. (Power Speed) Welding Not Continuous Recommended 5 kW/kVA Total From...

  • Page 27: Process Switch

    6-4. Process Switch Process Switch When switch is in a Stick mode, select one Stiff Arc (E6010) (Position 4) - This setting of four dig settings to provide additional am- provides a high dig/arc force for open root Y Weld output terminals are energized perage during short arc length conditions vertical down joints where additional when Process switch is in an Elec-...

  • Page 28: Stick Start Procedure − Scratch Start Technique

    6-5. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: Electrode Workpiece Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

  • Page 29: Remote Amperage Control

    6-7. Remote Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-7). With remote control connected, weld output in a CC mode (Stick, TIG) is determined by a combination of front panel and remote control voltage/ amperage settings.

  • Page 30: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Circuit Breakers Y If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord. Weld output and 60 Hz generator power output at receptacles RC1 and RC2 are not always available at the same time.

  • Page 31: Variable Frequency (Hz) Generator Power Receptacle Rc3

    7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 Y Do not operate equipment re- quiring a constant frequency from variable frequency re- ceptacle RC3. 120 V 20 A Variable Frequency AC Receptacle RC3 Receptacle supplies single-phase power continuously. Frequency (Hz) of generator power output changes with engine speed.

  • Page 32: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each duplex receptacle shares a load 240 V...

  • Page 33: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Y Stop engine before maintaining. See Engine Manual and Maintenance Label for impor- Recycle tant start-up, service, and storage information. Service engine more often if used in severe conditions. fluids. To be done by Factory Authorized Service Agent. Every 8 h Wipe up spills.

  • Page 34: Maintenance Label

    8-2. Maintenance Label NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. OM-4430 Page 30...

  • Page 35: Servicing Optional Spark Arrestor

    8-3. Servicing Optional Spark Arrestor Y Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. Tools Needed: 1/4 in 803 983−A / Ref 216 172−B 8-4. Servicing Air Cleaner Y Stop engine.

  • Page 36: Changing Engine Oil, Oil Filter, And Fuel Filter

    8-5. Changing Engine Oil, Oil Filter, And Fuel Filter Y Stop engine and let cool. Oil Drain Valve Oil Filter Change engine oil and filter accord- ing to engine manual. Y Close valve and valve cap before adding oil and run- ning engine.

  • Page 37: Overload Protection

    8-6. Overload Protection Y Stop engine. Open left side door. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. Circuit Breaker CB4 CB4 protects the stator winding supplying 24 volt ac output to Re- mote receptacle RC4.

  • Page 38: Troubleshooting

    8-7. Troubleshooting A. Welding Trouble Remedy No weld output. Check weld control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-2 and 6-7). Check and secure connections to Remote receptacle RC4 (see Sections 5-7). Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
  • Page 39 Trouble Remedy Lack of high frequency; difficulty in Use proper size tungsten for welding amperage. establishing Gas Tungsten Arc Weld- ing arc. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.). Check cables and torch for cracked or deteriorated insulation or bad connections.
  • Page 40 D. Engine Trouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 8-6). Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine does not start.
  • Page 41 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)

  • Page 42: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models OM-4430 Page 38...
  • Page 43 218−723−B OM-4430 Page 39...
  • Page 44 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)

  • Page 45: Section 10 − Generator Power Guidelines

    SECTION 10 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 10-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...
  • Page 46 10-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 47 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 48 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 49 10-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 50 10-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Fused Utility Welding Disconnect Electrical Generator Transfer Switch Switch Service Output (If Required) Essential Loads Y Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-...
  • Page 51 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 52: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 10 11 26 Fig.11−2 51 Fig.11−3 803 987−A Figure 11-1. Main Assembly OM-4430 Page 48...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ....211366 Panel, Side RH ..........
  • Page 54 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly (Continued) ..DC−Z ..214824 Stabilizer Assy, (Includes) .........
  • Page 55 Item Part Description Quantity Figure 11-2. Generator (Figure 11-1 Item 26) ....+218746 Stator, Generator ..........
  • Page 56 Hardware is common and not available unless listed. 803 989−A Figure 11-3. Panel, Front w/Components OM-4430 Page 52...
  • Page 57 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Panel, Front w/Components (Figure 11-1 Item 51) ......Nameplate (Order By Model &...
  • Page 58 Note Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs. Description Quantity Wiring Harnesses ....218735 Harness, Wrg Unit (includes) .
  • Page 59 Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.

  • Page 60: Options And Accessories

    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 2004 Miller Electric Mfg. Co. 10/04...

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