Miller Electric Bobcat 250 manual Installation, Installing Welding Generator

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. A complete Parts List is available at www.MillerWelds.com

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

! Do not lift unit from end.

OR

Location / Airflow Clearance

OR

18in

(460 mm)

 

18 in

18 in

(460 mm)

(460 mm)

 

18 in

18 in

(460 mm)

(460 mm)

 

Mounting

OR

Inadequate support.

! Do not use flexible mounts.1

Grounding 2

3

! Bed liners, shipping skids, and some running gears in-

GND/PE

sulate the welding generator from the vehicle frame. Al-

 

 

ways connect a ground wire from the generator equip-

 

 

ment grounding terminal to bare metal on the vehicle

 

 

frame as shown.

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.

! Do not mount unit by support- ing the base only at the four mounting holes. Use cross- supports to adequately sup- port unit and prevent damage to base.

! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

! If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.

NOTICE − Do not install unit where air flow is restricted or engine may overheat.

Mounting:

1 Cross-Supports

Mount unit on flat surface or use cross-supports to support base.

Grounding:

2Equipment Grounding Terminal (On Front Panel)

3Grounding Cable (Not Supplied)

4Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insu- lated copper wire.

4

install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712

OM-4419 Page 17

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Contents File Engine Drive OM-4419Visit our website at 2007−05From Miller to You Table of Contents 10-2 10-110-3 11-1Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicauxSymbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsDimensions For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesRobin-PoweredUnit 560 lb 254 kg DimensionsFuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered UnitsFor CC/AC Mode For CC/DC Mode For CV/DC ModeVolt-Ampere Curves Generator Power Curve Duty Cycle100% Duty Cycle at 250 Amperes Installing Welding Generator − Installation0000 Engine Prestart Checks Robin-Powered UnitsOil Check OilOpen top service door Engine Prestart Checks Kohler-Powered UnitsConnecting Or Replacing the Battery Installing Exhaust PipeConnecting The Battery Connect negative − cable last + −Tools Needed Correct Installation Connecting to Weld Output TerminalsStop engine Work Weld Output TerminalSelecting Weld Cable Sizes Front Panel Controls − Operating the Welding GeneratorInfrequently Cold Weather Engine OperationLoaded Frequently LoadedTypical Settings For 7018 1/8 in Electrode Typical Stick Welding Connections And Control SettingsWork Clamp Electrode Holder Tools Needed 3/4Solid Wire Applications Typical MIG Welding Connections And SettingsFine Control, Weld Process switch Settings Quick connector Be sure to use the correct size weld cables see SectionFine Control, Weld Process switch Settings Self-Shielded Flux Core Wire ApplicationsAluminum On 1/8 in Material Typical Settings For 4043Work Lines and may not suit all applications Cables see Section− Operating Auxiliary Equipment Generator Power ReceptaclesWiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 Receptacle100 Routine Maintenance Robin-Powered Units200 500Maintenance Label Robin-Powered Units Servicing Air Cleaner Robin-Powered Units Overload Protection Robin-Powered UnitsStop engine. Disconnect negative − battery cable Full Oil Fill Oil CheckStop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterIdle Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsTurn idle speed screw for fine adjustments Weld/Power Speed AdjustmentMaterial Thickness Reference Chart Servicing Optional Spark Arrestor Robin-Powered UnitsHours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4419 Routine Maintenance Kohler-Powered UnitsMaintenance Label Kohler-Powered Units Servicing Air Cleaner Kohler−Powered Units 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveClose valve and valve cap before adding oil Full Up fuelTurn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsWelding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Check receptacle wiring and connectionsCheck fuel level Switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams228 460-A Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090Electrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint Or LessTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Holding And Positioning Welding Gun − MIG Welding Gmaw GuidelinesPush Perpendicular Drag Short Normal LongSlow Normal Fast Gun Movement During Welding 15-7 Troubleshooting − Excessive Spatter 15-8 Troubleshooting − Porosity15-9 Troubleshooting − Excessive Penetration Lack Of Penetration − shallow Fusion between weld metalImproper joint preparation Unsteady hand Support hand on solid surface or use two hands Common MIG Shielding Gases ApplicationFillet Page Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s