Miller Electric Bobcat 250 manual Routine Maintenance Kohler-Powered Units

Page 41

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

SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)

9-1. Routine Maintenance (Kohler-Powered Units)

 

 

 

 

! Stop engine before maintaining.

 

 

 

Recycle engine

. See Engine Manual and Maintenance Label

 

 

 

fluids.

for important start-up, service, and storage

 

 

 

information. Service engine more often if

 

 

 

 

 

 

 

 

used in severe conditions.

n = Check

Z = Change

~ = Clean

l = Replace

Reference

* To be done by Factory Authorized Service Agent

 

 

Every

 

 

Section 5-3

8

 

 

 

Hours

 

 

 

n Fuel Level

n Oil Level

~ Oil, Fuel Spills

 

Every

 

 

Section 9-7

20

 

 

 

Hours

 

 

 

n~ Spark Arrestor Screen

 

 

 

Every

 

 

Section 9-3

25

 

 

 

Hours

 

 

 

~ Air Cleaner Wrapper

 

 

 

Every

 

 

 

50

 

 

 

Hours

 

 

 

~ Weld Terminals

 

 

 

Every

 

 

Engine

100

 

 

Manual,

Hours

 

 

Section 9-3,

 

 

 

9-4

~ Battery Terminals

~ Cooling System

Z Oil

nl Air Cleaner Element

Every

 

 

Engine

200

 

 

Manual,

Hours

 

 

Section 9-4

l Unreadable Labels

n Spark Plug Gap

Z Oil Filter

l Fuel Filter

Every

 

 

Engine

500

 

 

Manual

Hours

 

 

 

nl Weld Cables

n~ Slip Rings*

 

 

 

nl Brushes*

 

 

OM-4419 Page 37

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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 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 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 UnitsVolt-Ampere Curves For CC/AC ModeFor CC/DC Mode For CV/DC Mode 100% Duty Cycle at 250 Amperes Generator Power CurveDuty Cycle 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 Stop engine. Disconnect negative − battery cable Servicing Air Cleaner Robin-Powered UnitsOverload Protection Robin-Powered Units 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 RemedyCheck fuel level Engine TroubleshootingCheck receptacle wiring and connections 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 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 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 − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Holding And Positioning Welding Gun − MIG Welding Gmaw GuidelinesSlow 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 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