PRO 300

Quick

Specs

Industrial Applications

Pipe Welding

Structural Steelwork

Fabrication

Maintenance

Repair

Processes

Stick (SMAW)

MIG (GMAW)

Flux Cored (FCAW)

DC TIG (GTAW)

Air Carbon Arc (CAC-A)

Rated: 3/16 in (4.8 mm) carbons,

Capable: 1/4 in (6.4 mm) carbons

Air Plasma Cutting and Gouging with optional Spectrum models

The Power of Blue .

®

The Professional Welder’s

Choice — designed with the professional in mind, the

PRO 300 is the best for ease of use, reliability and fuel economy.

Superior arc performance

• Four preset DIG settings (Stick)

• Hot Start ™ (Stick)

• Lift-Arc ™ TIG with Auto-Stop ™ and Crater-out

• MIG/FCAW arc performance

Tailored Arc Control (DIG) allows the arc characteristics to be changed for specific applications and electrodes. Smooth running

7018 or stiffer, more penetrating

6010 electrodes.

Simple-to-set controls require no elaborate procedure — just select process and weld!

Auto Remote Sense (ARS) detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/panel switch.

Improved!

Superior Arc

Performance!

Standard features include: Stick, Lift-Arc ™ TIG,

Flux Cored and MIG. Other features include digital preset weld meters, output contactor control, and automatic idle.

Issued February 2008 • Index No. ED/5.21

Engine-Driven Welder/

AC Generator

Output Range

DC Stick 40 – 410 A

DC TIG 20 – 410 A

FCAW/MIG 14 – 40 V

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

12,000 Watts Peak

10,000 Watts Continuous

Accu-Rated ™ – Not Inflated

Generator Power

Heavy-Duty Low-Speed

Industrial Engine Choices!

CATERPILLAR C1.5,

21.7 HP @ 1800 RPM industrial engine

Deutz D2008 L04,

24.3 HP @ 1800 RPM industrial engine

Designed to operate over 10,000 hours before the first basic overhaul. Backed by worldwide support and service.

Meter maintenance displays.

• Hour meter function

• Oil change interval

• High coolant temperature and low oil pressure shutdowns

• Low fuel shutdown — engine shuts downs before system runs out of fuel, making restarts easy.

Quiet operation: Improves work site communication.

Thermal overload protection prevents machine damage if the duty cycle is exceeded or airflow is blocked.

Optional Stainless Steel

Appearance Package provides additional exterior protection to withstand corrosive environments.

The Vault — ultimate control

board reliability. See page 4.

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

Engine is warranted 3 years by engine manufacturer.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

Web Site www.MillerWelds.com

2

Specifications

(Subject to change without notice.)

Weld

Mode

CC/DC

CV/DC

Weld Output

Range

20 – 410 A

Weld Output Rated at 104˚ F (40˚ C)

400 A, 23 VDC,

30% Duty Cycle

300 A, 32 VDC,

60% Duty Cycle

14 – 40 V

Max. Open-

Circuit Voltage

65

Generator Power Output

Rated at 104˚ F (40˚ C)

12,000 Watts Peak

10,000 Watts Continuous

Single-phase, 120/240 VAC,

83/42 A 60 Hz

Sound Levels at Rated

Output, 7 m (23 ft)

CAT:

71 dB (96 Lwa)

Deutz:

73 dB (98 Lwa)

Dimensions

H: 32 in

(813 mm)

W: 26-1/4 in

(667 mm)

D: 56 in

(1422 mm)

Net Weight

(without fuel)*

CAT:

Net: 1128 lb (512 kg)

Ship: 1150 lb (522 kg)

Deutz:

Net: 1208 lb (548 kg)

Ship: 1230 lb (558 kg)

CSA approved. Meets NEMA and IEC output ratings.

*Additional 82 lb (37 kg) when fuel tank is full.

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

Engine Brand

CATERPILLAR

C1.5

Deutz D2008

L04

Features

EPA Tier III indirect-injected liquid-cooled engine. Right side service access with intervals of

250 hrs for oil and filters.

HP

21.7

24.3

Type

3-cylinder, industrial liquid-cooled, diesel

4-cylinder, industrial liquid-cooled, diesel

Engine

Speeds

1850 RPM weld

(1500 RPM idle)

1800 RPM weld

(1500 RPM idle)

Fuel

Capacity

11.5 gal

(43.5 L)

Oil

Capacity

6 qt

(5.7 L)

Coolant

Capacity

6 qt

(5.7 L)

Automatic Engine

Shutdown

Low Oil Pressure,

High Coolant

Temperature,

Low Fuel Level

Performance Data

STICK MODE V/A CURVE – MAX DIG

100

90

80

70

60

50

40

30

20

MIN

300

MAX

10

0

0 100 200 300 400 500 600

DC AMPERES

MIG MODE V/A CURVE

100

80

60

40

MAX

20 MIN

0

0 100 200 300 400 500 600

DC AMPERES

GENERATOR POWER CURVE

150 300

125 250

100 200

75 150

50 100

25 50

0 0

0 20 40 60

AC AMPERES IN 240 V MODE

80

0 40 80 120

AC AMPERES IN 120 V MODE

160

FUEL CONSUMPTION CURVE

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

IDLE

0.00

0 50 100 150 200 250 300 350 400

DC WELD AMPERES

AT 100% DUTY CYCLE

DC TIG MODE V/A CURVE

100

90

80

70

60

50

40

30

20

10

0

0

MIN

300

MAX

100 200 300 400 500

DC AMPERES

SIMULTANEOUS WELDING AND POWER

Weld

Amperes

225

175

125

75

25

Total Power

Available (Watts) 120 V 240 V

3000

5000

5900

7300

10,000

25

41.6

49.2

60.8

83.5

12.5

20.8

24.6

30.4

41.7

Function Guide

1. Self-calibrating digital weld meters with meter maintenance displays.

2. Four Preset DIG Settings offer the best arc characteristics for different electrodes and joint designs. The amount of DIG determines how much amperage (heat) varies with Stick arc length. The combined

Process switch along with preset DIG settings make the PRO 300 easy to set without the complication of multiple switches.

3. Hot Start ™ provides positive Stick electrode starts making it easy to start all types of electrodes and it also works great for bead tie-ins.

4. Great MIG/FCAW Performance and Arc

Starts make the PRO 300’s arc best in its class. Easy to run all wires from .023 in solid wires to large diameter 5/64 in flux cored wires.

5. Lift-Arc ™ TIG with Auto-Stop ™ and

Crater-out (patents pending)

6. Standard 14-Pin Receptacle for simple connection of remote controls and wire feeders. 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. Weatherproof Lexan ® Nameplate is super durable and resists cracking and fading.

Color coding is for ease of operation.

8. Fuel Gauge displays engine hours and oil change interval information.

Low Fuel Shutdown shuts engine off prior to running out of fuel to prevent loss of fuel in the system, and make restarts easy.

Display will read noFUEL. Turn the machine off, add fuel, and restart.

9. Glow Plugs assist in cold weather starting.

10. Engine Control Switch is used to start the engine and then select between Auto Idle and High Speed Lock.

11. Amperage/Voltage Adjust Control

12. 120 VAC and 240 VAC Receptacles with

Circuit Breakers (optional 120 VAC GFCI receptacles available).

Note: For matching plug, order #119 172.

13. Weld Output Terminals

1

2

3

4

5

6

7

ARC START

with Lift-Arc ™

Lift at any angle Touch or scratch

Shielding gas

Arc Shielding gas

• Reduces or eliminates sticking

• Reduces or eliminates electrode/ work contamination

• Low open-circuit voltage

(approximately 10 volts)

Workpiece

ARC END

with Auto-Stop ™

While welding

Arc

Workpiece

Shielding gas

Lift up until arc ends

For Auto-Stop, lift up to terminate arc

Arc ends without flare

Move back down to maintain gas coverage

• Eliminates need for a remote control

• Maintains shielding gas coverage

• Eliminates tungsten and workpiece contamination

• Eliminates unwanted arc strikes outside the weld area

ARC END

with Crater-out

While welding To start Crater-out, press momentary contact switch

Shielding gas

Welding current ramps down

Arc

Workpiece

Maintain shielding gas coverage

• Maintains shielding gas coverage

• Eliminates tungsten and workpiece contamination

• Crater-out time allows for addition of filler

• Eliminates unwanted arc strikes outside the weld area

8

9

10

11

12

13

3

What Makes Miller Industrial Engine Drives So ?

Superior Circuit Board Design

Miller’s critical circuit boards are engineered to carry low power and low heat to reduce thermal stress and minimize expansion and contraction. In contrast, our competitor’s boards carry high power and high heat, making them more vulnerable to failure.

“The Vault” Makes Upgrading to Miller CC/CV Units

Worry-Free

Concerns with circuit board reliability have resulted in some operators steering clear of CC/CV welder/generators — even though they offer a superior arc and multiple welding processes. Miller’s circuit board reliability isn’t a concern since all PRO 300 and Big

Blue multiprocess industrial engine drives feature the Vault.

Created out of two aluminum halves sealed with silicone, as well as watertight harness connections, the Vault provides a clean circuit board environment, protecting the electronics — and controlling output — in heavy industrial applications. No other competitor protects their electronics with a sealed vault, leaving critical circuit boards exposed to harsh elements that can disrupt the machine’s electronics, and therefore, its operation.

Rigorous Testing for Tough,

Real-World Conditions

To prove our machines go to the limit, Miller industrial engine drives are put to the test in very extreme environmental conditions.

• Airborne Dust and Sand —

Critical components are exposed to abusive airborne particles in a special testing chamber for weeks, helping make sure they’ll operate while facing extreme levels of dirt, dust or sand on the job site.

• Humidity and Corrosion —

Inside Miller’s Houston testing room, critical components are subjected to extended moisture and corrosive salt exposure to ensure they’ll run even when exposed to humid climates, corrosive coastal environments, and driving rain.

• Temperature Extremes — Miller’s industrial engine drives are tested to ensure performance in scorching heat. All Miller engine driven machines are weld rated at 104˚ F, but actual tests are conducted up to 122˚ F to assure peak performance.

• Jobsite/Over-the-Road Abuse — Miller industrial engine drives are shaken for hours on transportation bed simulators, subjected to severe vibration, and test-dropped and jerked to ensure they’ll withstand the stresses that can shut down competitive machines.

• Continuous Operation — Miller’s industrial engine drives run day and night, in all weather conditions, to assure they’ll perform without interruption in the field.

4

“The PRO 300 worked year ’round and never caused any problems. We were amazed at the cold-weather starting. A machine that doesn’t run means we have to work overtime… secondly, you don’t want to have a crew standing around at

$200 an hour while someone tries to start the machine.”

Edward McNaughton, Nordcap Steel Docks

Why Industrial Engine Drive Customers Choose Miller

The ultimate test of Miller’s reliability is how it performs in the field. The quote on the left provide a glimpse of how

Miller industrial engine drives perform for customers. Read the full stories, and many others demonstrating Miller’s superior reliability, at MillerWelds.com.

Genuine Miller Accessories

Plasma Cutting

Female

Receptacle

Adapter Cord, Full KVA #300 158 Field

NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to common

Millermatic ® and Spectrum ® 240 V plug.

Full KVA Plug Kit

#119 172 Field

120/240 VAC, 50 amp plug

(NEMA 14-50P) to fit full

KVA receptacle.

Cold Weather Starting Aid #195 056 Field

120 V block heater.

Note: All models come standard with preheaters

(glow plugs).

Spark Arrestor (Muffler) Kit #195 291 Field

Prevents particles from leaving the muffler that could potentially start a fire. Mandatory when operating on California grasslands, brush, or forest-covered land, and all national forests. For other areas, check your state and local laws.

FA-1D Lockable Flame

Arrestor Fuel Cap #043 947

Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank.

Spectrum ® 375 X-TREME ™

Spectrum ® 375 X-TREME ™

#907 339 (not shown)

See Lit. Index No. PC/9.2.

#907 303 with X-CASE ™

Spectrum ® 625 #907 058

See Lit. Index No. PC/9.5.

Spectrum 2050 #903 777-01-2

See Lit. Index No. PC/7.0.

MIG (GMAW) or Flux Cored (FCAW)

Millermatic ®

Passport ® Plus

#907 401

Portable, all-in-one MIG package features ultimate arc performance, selfcontained gas bottle, and flexibility to plug into 115 or 230 V power with Miller exclusive Multi-Voltage

Plug. See Lit. Index No. DC/12.53.

Protective Cover #195 301 Field

Blue water-resistant cover with Miller logo resists stains and mildew, and protects the finish of your welder.

Stick (SMAW) Welding

Weld Leads

#173 851 2/0, 350 A, 100% duty cycle,

50 ft stinger, 50 ft work cable

#043 952 2/0, 300 A, 100% duty cycle,

100 ft stinger, 50 ft work cable

SuitCase

™

X-TREME ™ 8VS Wire Feeder

#300 093

SuitCase

™

X-TREME ™ 12VS Wire Feeder

#195 500

Lightweight, voltage-sensing wire feeders include secondary contactor and gas valve.

Require drive roll kit. See Lit. Index No.

M/6.41.

MIG (GMAW)/Flux Cored (FCAW) Guns

Miller produces a com plete line of dependable MIG guns. See Lit. Index Nos.

AY/15.0, AY/16.0 and AY/17.0.

Spoolmatic ® 30A

Spool Gun

#130 831

Air-cooled, 200-amp,

1-lb spool gun for aluminum MIG. See Lit. Index No. M/1.73.

WC-24 Control #137 549

Use with Spoolmatic 30A.

XR ™ Wire Feeders and Guns

Push-pull system designed to handle difficult-to-feed soft alloy wires such as aluminum. See Lit. Index No. M/1.7,

M/1.71, and M/1.73.

TIG (GTAW) Welding

HF-251 Series #042 388

HF-251D-1, 115 VAC

High-frequency arc starter and stabilizer. See

Accessory Lit. Index No.

AY/5.0.

Multiple Operator Welding

The XMT 304, CST 280 and Dynasty 200 power sources can be run off the machine’s generator to provide two arcs with only one engine. There is no arc interaction under

180 amps.

XMT ® 304

#903 471 and

#903 471-01-1 only

See Lit. Index No. DC/18.8.

CST ™ 280

#907 244, #907 244-01-1

#907 251, #907 251-01-1

See Lit. Index No. DC/29.55.

Dynasty ® 200

Series

#907 099

#907 099-01-1

See Lit. Index

No. AY/4.8.

SuitCase

™

8RC Wire Feeder #194 938

SuitCase

™

12RC Wire Feeder #194 940

Lightweight and flexible enough to run a variety of wires up to .062 in diameter.

Comes standard with remote voltage control. See Lit. Index No. M/6.5.

5

Genuine Miller Accessories

(continued)

Remote Controls

RHC-14 Hand Control

#129 340

Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x

3-1/4 in (102 x 102 x 82 mm). Includes

20 ft (6 m) cord and 14-pin plug.

RMLS-14 #129 337 14-pin plug

Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and back for momen tary contact. Includes 20 ft (6 m) cord.

RFCS-14 HD Foot Control #194 744

Heavy-duty foot current and contactor control. Includes 20 ft (6 m) cord and

14-pin plug.

RMS-14 On/Off Control #187 208

Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5 ft (8 m) cord and 14-pin plug.

RCC-14

Remote

Contactor and

Current Control #151 086 14-pin plug

Rotary-motion fingertip control fastens to

TIG torch using two Velcro ® straps.

Includes 28 ft (8.5 m) control cord.

PRHC-14 Hand Control

#195 511

Complete current or voltage control brings

120 volts GFCI power to work area in a single cord.

Housed in a durable light aluminum case and includes 125 ft (38 m) cord with plugs.

Extension Cords for 14-Pin

Remote Controls or 24 VAC Wire Feeders

#122 973 25 ft (7.6 m)

#122 974 50 ft (15.2 m)

#122 975 75 ft (23 m)

Trailers and Hitches

(Note: Trailers are shipped unassembled.)

Mounting Specifications

F

4 holes

Front Panel

A B

Shown with ball hitch, fenders and lights.

Mid-Frame Trailer #195 481

1500 lb (680 kg) capacity highway trailer.

Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Comes with jack stand, and safety chain (order hitch separately).

Ball Hitch, 2 in #195 493

Lunette Eye 2-1/2 in (64 mm) #043 824

Fender Kit #195 482

Light Kit #195 483

Requires fender kit.

Cable Tree #195 023

Provides an area to conveniently wrap weld cables and extension cords.

HWY-224 Trailer

#043 805 For highway use.

OFR-224 Trailer

#043 802 For off-road use.

A 2650 lb (1202 kg) capacity trailer.

Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, 2 in (50 mm) ball hitch. HWY-224 also includes fenders and lights.

Note: Trailer is shipped unassembled.

Cable Tree #043 826

Provides an area to conveniently wrap weld cables and extension cords.

Lunette Eye 2-1/2 in (64 mm) #043 824

Specifications

(Subject to change without notice.)

A. 27-3/4 in (705 mm)

B. 26-1/4 in (667 mm)

C. 52 in (1321 mm)

D. 2 in (51 mm)

E. 56 in (1422 mm)

F. 9/16 in (14 mm) dia.

C

D

E

Height: 32 in

(813 mm)

Width: 26-1/4 in

(667 mm)

Depth: 56 in

(1422 mm)

Model

Mid-Frame

HWY-224

OFR-224

Gross Axle

Weight Rating

1500 lb

(680 kg)

3500 lb

(1588 kg)

Gross Vehicle

Weight Rating

1666 lb

(755 kg)

2960 lb

(1343 kg)

Net

Payload

1424 lb

(645 kg)

2650 lb

(1202 kg)

Height of Bed

18-1/2 in

(470 mm)

18-1/2 in

(470 mm)

Road

Clearance

6-1/2 in

(165 mm)

7-1/2 in

(191 mm

Track (Center to center of tires)

45 in

(1143 mm)

52 in

(1321 mm

Standard Tires

(Standard rating or P-size rating)

B78-13

B78-13

Dimensions

Length: 98 in (2489 mm)

Width: 52 in (1321 mm)*

Length: 122-1/2 in (3112 mm)

Width: HWY– 61 in (1549 mm)*

OFR–58-1/2 in (1486 mm)

Net

Weight

242 lb

(110 kg)

355 lb

(161 kg)

* Width at outside of fenders.

6

Typical Installations

Stick (SMAW) Basic Equipment

Flux-Cored (FCAW) Basic Equipment

SuitCase ™ X-TREME ™

SuitCase ™ X-TREME ™

8VS #300 093

12VS #195 500

MIG (GMAW) Basic Equipment

SuitCase ™ 8RC #194 938

SuitCase ™ 12RC #194 940

Aluminum MIG (GMAW) Basic Equipment

Spoolmatic ®

WC-24

30A #130 831

#137 549

TIG (GTAW) Basic Equipment

Dynasty ® 200 Series

HF-251D-1 #042 388*

*TIG power cable adapter required

Plasma Basic Equipment

Spectrum ® 375 X-TREME ™ #907 303

Spectrum ® 375 X-TREME ™ with X-CASE ™

Spectrum

Spectrum

®

®

625

2050

#907 339

#907 058

#903 777-01-2

Stick Electrode

Work

14-Pin

X-TREME 8VS/

X-TREME 12VS

Feeder

SuitCase

8RC/12RC

Flux Cored Gun

Work

MIG Gun

Work

Aluminum MIG with

Spoolmatic 30A Gun

14-Pin

WC-24

14-Pin

HF-251D-1

TIG

Torch

Work

Work

Cutting Torch

Spectrum

Work

7

Ordering Information

Equipment and Options

PRO 300 CC/CV

Stock No.

#907 144

#907 144-01-1

#907 144-02-1

#907 399 PRO 300 D CC/CV

Accessories

Cold Weather Starting Aid

Spark Arrestor (Muffler) Kit

FA-1D Lockable Flame Arrestor Fuel Cap

Adapter Cord, Full KVA

Full KVA Plug

Protective Cover

Remote Controls and Switches

Multiple Operator Welding

XMT ® 304 CC/CV

CST ™ 280 CC/DC

#195 056

#195 291

#043 947

#300 158

#119 172

#195 301

#903 471

#903 471-01-1

#907 244

#907 244-01-1

#907 251

#907 251-01-1

#907 099

#907 099-01-1

Dynasty ® 200 SD

Dynasty ® 200 DX

Plasma Cutting

Spectrum ® 375 X-TREME ™ (only)

Spectrum ® 375 X-TREME ™ with X-CASE ™

Spectrum ® 625

Spectrum ® 2050

MIG/Flux Cored Welding

Millermatic ® Passport ® Plus

SuitCase ™ X-TREME ™ 8VS

SuitCase ™ X-TREME ™ 12VS

SuitCase ™ 8RC

SuitCase ™ 12RC

MIG (GMAW) and Flux Cored (FCAW) Guns

Spoolmatic ® 30A Spool Gun

WC-24 Control

XR

™

Wire Feeder Control and Guns

TIG Welding

HF-251 Series

Trailers and Hitches

Mid-Frame Trailer

Ball Hitch, 2 in

Lunette Eye

Fender Kit

Light Kit

Cable Tree

HWY-224 Trailer

OFR-224 Trailer

Lunette Eye, 2-1/2 in

Cable Tree

Date:

#907 303

#907 339

#907 058

#903 777-01-2

#907 401

#300 093

#195 500

#194 938

#194 940

#130 831

#137 549

#042 388

#195 481

#195 493

#043 824

#195 482

#195 483

#195 023

#043 805

#043 802

#043 824

#043 826

Description

CAT CC/CV

CAT CC/CV, 120 V Block Heater

CAT CC/CV, 120 V Block Heater, Stainless Steel Package

Deutz CC/CV

Field, 120 V block heater

Field

Field

Field

Field

Field

See page 5

See Lit Index No. DC/18.8

220-230/460–575 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55

220-230/460 – 575 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55

208-230/400 – 460 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55

208-230/400 – 460 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55

Basic controls for AC/DC TIG/Stick, 120 – 460 VAC. See Lit Index No. AY/4.8

Full feature controls for AC/DC TIG/Stick, 120–460 VAC. See Lit Index No. AY/4.8

See Lit Index No. PC/9.2

See Lit Index No. PC/9.2

See Lit Index No. PC/9.5

See Lit Index No. PC/7.0

Includes gas bottle and MVP. See Lit. Index No. DC/12.53

See Lit Index No. M/6.41

See Lit Index No. M/6.41

See Lit Index No. M/6.5

See Lit Index No. M/6.5

See Lit Index Nos. AY/15.0, AY/16.0 and AY/17.0

Requires WC-24 Control. See Lit. Index No. M/1.73

See Lit. Index No. M/1.5

See Lit. Index No. M/1.7, M/1.71, and M/1.73

115 VAC. See Lit. Index No. AY/5.0

Trailer with jack stand and safety chain. Order hitch separately

Requires fender kit

Trailer-mounted cable holder

Trailer with lights, fenders and 2 in ball hitch. For highway use

Trailer with 2 in ball hitch. For off-road use

For HWY-224 or OFR-224

Trailer-mounted cable holder for HWY-224 or OFR-224

Total Quoted Price:

Qty. Price

Distributed by:

Litho in USA