Miller Electric Bobcat 250 manual Typical Settings For 4043, Aluminum On 1/8 in Material, Work

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

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun

Tools Needed:

Typical Settings For 4043 (.035)

Aluminum On 1/8 in Material:

 

3/4 in

 

 

Note Coarse Range and Weld

 

Process switch settings.

 

10

9

8

Work

Connect to unused

 

contactor terminal.

12

6

5

Plug and sensing lead not used in this application.

Left Side View

2

1

3

11

 

 

4

5

6

7

802 750-B / 228 201-B

 

 

 

 

 

 

. This section provides general guide-

. Be sure to use the correct size weld

 

Typical Settings For 4043 (.035)

 

lines and may not suit all applications.

cables (see Section 5-7).

 

Aluminum On 1/8 in Material:

 

 

 

 

1

Weld Control

Route weld cable from welding generator

 

> Set Weld Process Selector switch to

2

Spoolgun

Electrode terminal through reed switch to

 

 

Wire + (DCEP) position.

unused contactor terminal. Connect weld

 

 

 

 

 

 

 

3

Optional Contactor (Recommended)

cable from spoolgun to weld control weld ter-

 

> Set Coarse Range switch to Wire/Low

4

Reed Switch

minal (item 6).

 

 

 

(17-22 volts) position.

 

 

 

 

5

Weld Cable (Customer-Supplied)

Connect work cable to welding generator

 

> Set Fine Control to desired voltage

6

Weld Control Weld Terminal

Work terminal.

 

 

Insert trigger control plug (item 11) into weld

 

 

(arc length). Start with a low voltage

7

Weld Power Cable From Spoolgun

 

 

setting (about 4) to prevent burnback.

control receptacle. Tighten threaded collar.

 

 

8

Work Clamp

 

 

 

Connect ac power cord (item 12) to 120 volt

 

> Set wire feed speed between 240-270

9

Gas Hose

 

ac receptacle on welding generator.

 

 

ipm. For 1/4 in. and thicker materials,

10

Argon Cylinder

Connect gas hose from spoolgun to regula-

 

 

set Coarse Range switch to Wire/High

11

Trigger Control Cord

tor on Argon bottle.

 

 

 

and Fine Control to 6. Increase/de-

 

 

 

crease Fine Control setting to in-

 

 

 

 

 

 

12

Input Power Cord

Reinstall weld control wrapper.

 

 

crease/decrease arc length.

OM-4419 Page 28

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Contents OM-4419 File Engine DriveVisit our website at 2007−05From Miller to You Table of Contents 10-1 10-210-3 11-1Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, and Operating Angles Dimensions For Units With Optional Running GearRobin-PoweredUnit 560 lb 254 kg DimensionsFuel Consumption Robin-Powered Units Fuel Consumption Kohler-Powered UnitsVolt-Ampere Curves For CC/AC ModeFor CC/DC Mode For CV/DC Mode 100% Duty Cycle at 250 Amperes Generator Power CurveDuty Cycle − Installation Installing Welding GeneratorEngine Prestart Checks Robin-Powered Units 0000Oil Check OilEngine Prestart Checks Kohler-Powered Units Open top service doorInstalling Exhaust Pipe Connecting Or Replacing the BatteryConnecting The Battery Connect negative − cable last + −Connecting to Weld Output Terminals Tools Needed Correct InstallationStop engine Work Weld Output TerminalSelecting Weld Cable Sizes − Operating the Welding Generator Front Panel ControlsCold Weather Engine Operation InfrequentlyLoaded Frequently LoadedTypical Stick Welding Connections And Control Settings Typical Settings For 7018 1/8 in ElectrodeWork Clamp Electrode Holder Tools Needed 3/4Typical MIG Welding Connections And Settings Solid Wire ApplicationsFine Control, Weld Process switch Settings Quick connector Be sure to use the correct size weld cables see SectionSelf-Shielded Flux Core Wire Applications Fine Control, Weld Process switch SettingsTypical Settings For 4043 Aluminum On 1/8 in MaterialWork Lines and may not suit all applications Cables see SectionGenerator Power Receptacles − Operating Auxiliary EquipmentSimultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 ReceptacleRoutine Maintenance Robin-Powered Units 100200 500Maintenance Label Robin-Powered Units Stop engine. Disconnect negative − battery cable Servicing Air Cleaner Robin-Powered UnitsOverload Protection Robin-Powered Units Oil Fill Oil Check FullStop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterAdjusting Engine Speed Robin-Powered Units Idle Speed AdjustmentTurn idle speed screw for fine adjustments Weld/Power Speed AdjustmentServicing Optional Spark Arrestor Robin-Powered Units Material Thickness Reference ChartRoutine Maintenance Kohler-Powered Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4419Maintenance Label Kohler-Powered Units Servicing Air Cleaner Kohler−Powered Units Stop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterClose valve and valve cap before adding oil Full Up fuelAdjusting Engine Speed Kohler-Powered Units Turn idle speed screw for fine ad- justmentsOverload Protection Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered Units− Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble RemedyCheck fuel level Engine TroubleshootingCheck receptacle wiring and connections − Parts List Switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts− Electrical Diagrams Circuit Diagram For Welding Generator228 460-A − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-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 Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090Conditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint Or LessTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead − MIG Welding Gmaw Guidelines Holding And Positioning Welding GunSlow Normal Fast Push Perpendicular DragShort Normal Long Gun Movement During Welding 15-9 Troubleshooting − Excessive Penetration 15-7 Troubleshooting − Excessive Spatter15-8 Troubleshooting − Porosity Improper joint preparation Lack Of Penetration − shallowFusion between weld metal Unsteady hand Support hand on solid surface or use two hands Fillet Common MIG Shielding GasesApplication Page Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s