Miller Electric 302 User Manual

Processes (X-Ray Quality)

Stick (SMAW)
MIG (GMAW)

with voltage-sensing feeder

Flux Cored (FCAW)

with voltage-sensing feeder
DC TIG (GTAW)
Air Carbon Arc (CAC-A) Cutting

and Gouging (3/16 in carbons)

Output Range

DC Stick 25 – 300 A
DC TIG 10 – 300 A
MIG/FCAW 13 – 35 V

Generator Power Output Rated at 104˚ F (40˚ C)

5500 Watts Peak — 5000 Watts Continuous

Industrial Applications

Fabrication
Structural Steel Work
Process Plant Piping
Maintenance

Quick
Specs

Miller Legend®302

Gas/LP Engine-Driven

Welder/AC Generator

Issued January 2008 • Index No. ED/4.2

Superior arc performance

• Four preset DIG settings

• Adaptive Hot Start

™

• Lift-Arc™with Auto-Stop

™

• MIG/FCAW

See page 2 for more information.

Increased fuel capacity to
12 gallons means many hours

of run time before refueling.

See page 3 for fuel
consumption information.

Exclusive!

Digital meters use SunVision

™

technology so they are easy to read in

direct sunlight or shade.

The Power of Blue®.

Self-calibrating digital weld meters with
meter maintenance functions.

• Preset and actual weld amperage/voltage

• Hour meter function

• Oil change interval

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]

Welder/generator is warranted for 3 years, parts and labor.

Engine is warranted separately by the engine manufacturer.

Reduced sound level of 75.5 dB
(100.5 Lwa) at rated load. Quietest in its
class and quieter than most engine drives
in the industry!

More horsepower — 23 HP gas/
20 HP LP Kohler

®

. Fully enclosed case
provides: reduced sound levels, fully
protected engine, and utilizes the same
hole mounting pattern as past models.

Exclusive!

Low-speed

generator produces 5500

watts peak, 5000 watts
continuous at 1800 RPMs,
2400 watts (60 –120 Hz) at
all speeds.

Exclusive!

Multi-speed

welding to reduce noise.

Up to 240 amps at a quiet
3000 RPMs and powerful
300 amps at 3600 RPMs.

See pages 2 and 3 for more

machine features/benefits.

Exclusive!

High-Impact Protective Armor

• Protective armor with receptacle and

output stud covers provides a virtually
indestructible barrier from damage

• High-impact resistance in all temperatures
Other applications include: automotive
bumpers, tractor hoods and panels, lawn
mower decks, large structural parts, etc.

Output stud and receptacle covers required
by OSHA and CSA for job site safety.

Accu-Rated

™

– Not Inflated

Generator Power

2

Weld
Speed

3600 RPM

3000 RPM

1800 RPM

Welding
Mode

CV/DC

CC/DC

CV/DC

CC/DC

CV/DC

CC/DC

Process

MIG/FCAW

Stick/TIG

MIG/FCAW

Stick/TIG

MIG/FCAW

Stick/TIG

Weld Output Rated at
25 V (at 104°F/40°C)*

300 A, 100% Duty Cycle

280 A, 100% Duty Cycle

240 A, 100% Duty Cycle

240 A, 100% Duty Cycle

120 A, 100% Duty Cycle

120 A, 100% Duty Cycle

Amp/Volt
Ranges

13 –35 V

10–300 A

13–27 V

10 – 240 A

13–22 V

10 – 120 A

Single-Phase
Generator Power

Peak: 5500 watts
Continuous: 5000 watts

120/240 VAC, 42/21 A,
60 Hz at 1800 RPM

2400 watts, 120 VAC,
60 –120 Hz at all speeds

Sound Levels at
Rated Output,
7 m (23 ft)

75.5 dB
(100.5 Lwa)

73 dB
(98 Lwa)

66 dB
(91 Lwa)

Net
Weight**

580 lb
(263 kg)

Dimensions

H: 33 in (838 mm)
W: 20 in (508 mm)
D: 45-1/2 in (1156 mm)

Specifications (Subject to change without notice.)

Engine Brand/
Warranty

Kohler:
3-year mfg.

Horsepower (HP)

23 HP (gas),
20 HP (LP) at 3600 RPM

Weld Speed

3600 RPM
3000 RPM

Idle Speed

2400 RPM
1800 RPM

Type

Twin-cylinder, 4-cycle overhead valve,
industrial air-cooled gasoline or LP

Fuel
Capacity

12 gal
(45 L)

Low Oil Pressure
Shutdown

Standard

Oil Capacity

1.75 qt (1.7 L),
2 qt (1.9 L) with filter

Engine Specifications (Engines warranted separately by the engine manufacturer.)

*Rated at sea level. **Net weight without fuel.

1 7

8

9

2

4

5

6

3

Function Guide

1. Digital Meters display preset amperage or
voltage while not welding. Displays actual
amperage and voltage while welding and for
5 seconds after welding has stopped.

Meter Maintenance Functions*

• Hour Meter: with engine off, place Engine

Control switch in the first RUN/IDLE
position to view engine hours.

• Oil Change Interval: with engine off, place

Engine Control switch into the second
RUN/IDLE position to see hours before next
oil change. Oil hours start at 100 and count
down to 0 (oil change due).

Note: Negative hours indicated when past
recommended oil change interval.
To Reset: Flip Engine Control switch from the
RUN/IDLE to RUN position 3 times.

2. Four Preset DIG Settings* offer the best arc
characteristics for different electrodes and
joint designs. The combined DIG and
Process switch along with preset DIG
settings makes it easy to set without the
complication of multiple switches.

DIG Settings

• Soft arc and smooth 7018 performance.

• Medium-soft driving arc.

• Medium-stiff driving arc.

• Driving arc such as pipe welding.

3. Adaptive Hot Start

™

* (Stick) automatically

sets starting amperage for great arc starts.

4. Great MIG/FCAW Performance with
voltage-sensing wire feeders.

5. Lift-Arc

™

/Scratch Start TIG* with Auto-Stop

™

provides great DC starts with both starting
techniques. Auto-Stop allows the arc to be
stopped without the loss of shielding gas.

6. Standard 14-Pin Receptacle for simple
connection of remote controls (not for wire
feeder usage). It features Auto Remote

Sense™* which automatically switches from

Panel to Remote Amperage/ Voltage (A/V)
control with remote connected. Eliminates
confusion of the Panel/Remote A/V switch.

7. Front Panel Fuel Gauge* LEDs indicate
fuel level. The “E” LED lights only when
fuel is low.

8. Speed Control Switch locks engine speed
at 1800 RPM for uninterrupted 60 Hz
generator power and light welding loads.

9. Engine Choke Control

*Category Exclusive

GasolineLP

Derate outputs up to 5% when using LP fuel.