Miller Electric
Bobcat 250
manual
Troubleshooting
Specifications
Poor Weld Bead Characteristics
Install
Parts list
Electrical Diagrams
Symbol Usage
Welding Wire can cause injury
Dimension
Stick Welding Procedure
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Contents
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OM-4419
File Engine Drive
2007−05
From Miller to You
Table of Contents
10-3
10-1
10-2
11-1
Electric Shock can kill
Symbol Usage
Arc Welding Hazards
HOT Parts can cause severe burns
ARC Rays can burn eyes and skin
Fumes and Gases can be hazardous
Buildup of GAS can injure or kill
Welding can cause fire or explosion
Engine Hazards
Compressed Air Hazards
Fire or Explosion hazard
Welding Wire can cause injury
HOT Parts can cause burns and injury
Falling Unit can cause injury
EMF Information
Principal Safety Standards
California Proposition 65 Warnings
Radiation can cause interference
UN Choc Électrique peut tuer
Signification des symboles
− Consignes DE Sécurité − Lire Avant Utilisation
Indique des instructions spécifiques
LE Soudage peut provoquer un in cendie ou une explosion
DES Pièces Chaudes peuvent provoquer des brûlures graves
LES 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
LES Fils DE Soudage peuvent provoquer des blessures
LE Surchauffement peut endom- mager le moteur électrique
DES Organes Mobiles peuvent provoquer des blessures
’EMPLOI Excessif peut
Information EMF
Proposition californienne 65 Avertissements
Principales normes de sécurité
En ce qui concerne les implants médicaux
Weld, Power, and Engine Specifications
− Specifications
Symbol Definitions
− Definitions
Robin-PoweredUnit 560 lb 254 kg
Dimensions, Weights, and Operating Angles
Dimensions For Units With Optional Running Gear
Dimensions
Fuel Consumption Robin-Powered Units
Fuel Consumption Kohler-Powered Units
Volt-Ampere Curves
For CC/AC Mode
For CC/DC Mode For CV/DC Mode
100% Duty Cycle at 250 Amperes
Generator Power Curve
Duty Cycle
− Installation
Installing Welding Generator
Oil Check
Engine Prestart Checks Robin-Powered Units
0000
Oil
Engine Prestart Checks Kohler-Powered Units
Open top service door
Connecting The Battery Connect negative − cable last
Installing Exhaust Pipe
Connecting Or Replacing the Battery
+ −
Stop engine
Connecting to Weld Output Terminals
Tools Needed Correct Installation
Work Weld Output Terminal
Selecting Weld Cable Sizes
− Operating the Welding Generator
Front Panel Controls
Loaded
Cold Weather Engine Operation
Infrequently
Frequently Loaded
Work Clamp Electrode Holder
Typical Stick Welding Connections And Control Settings
Typical Settings For 7018 1/8 in Electrode
Tools Needed 3/4
Fine Control, Weld Process switch Settings Quick connector
Typical MIG Welding Connections And Settings
Solid Wire Applications
Be sure to use the correct size weld cables see Section
Self-Shielded Flux Core Wire Applications
Fine Control, Weld Process switch Settings
Work
Typical Settings For 4043
Aluminum On 1/8 in Material
Lines and may not suit all applications Cables see Section
Generator Power Receptacles
− Operating Auxiliary Equipment
Current Available in Amperes 240
Simultaneous Weld And Power
Wiring Optional 240 Volt Plug
Receptacle
200
Routine Maintenance Robin-Powered Units
100
500
Maintenance Label Robin-Powered Units
Stop engine. Disconnect negative − battery cable
Servicing Air Cleaner Robin-Powered Units
Overload Protection Robin-Powered Units
Stop engine and let cool
Oil Fill Oil Check
Full
Oil Drain Valve 2 ID x 7 in Hose Oil Filter
Turn idle speed screw for fine adjustments
Adjusting Engine Speed Robin-Powered Units
Idle Speed Adjustment
Weld/Power Speed Adjustment
Servicing Optional Spark Arrestor Robin-Powered Units
Material Thickness Reference Chart
Routine Maintenance Kohler-Powered Units
Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4419
Maintenance Label Kohler-Powered Units
Servicing Air Cleaner Kohler−Powered Units
Close valve and valve cap before adding oil Full
Stop engine and let cool Oil Drain Valve
2 ID x 7 in Hose Oil Filter
Up fuel
Adjusting Engine Speed Kohler-Powered Units
Turn idle speed screw for fine ad- justments
Overload Protection Kohler-Powered Units
Servicing Optional Spark Arrestor Kohler-Powered Units
Generator Power Troubleshooting
− Troubleshooting
Welding Troubleshooting
Trouble Remedy
Check fuel level
Engine Troubleshooting
Check receptacle wiring and connections
Recommended Spare Parts
− Parts List
Switch S2, and throttle solenoid TS1
Recommended Spare Parts
− Electrical Diagrams
Circuit Diagram For Welding Generator
228 460-A
Grounding Generator To Truck Or Trailer Frame
− Generator Power Guidelines
Selecting Equipment
Electrically Bond Generator
Use ground device as stated in electrical codes
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Amperes x Volts = Watts
Industrial Motors Rating Starting Watts Running Watts
Approximate Power Requirements For Industrial Motors
Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Single-Phase Induction Motor Starting Requirements
Power Required To Start Motor
How Much Power Can Generator Supply?
KVA/HP x HP x 1000 / Volts = Starting Amperage
Typical Connections To Supply Standby Power
Selecting Extension Cord Use Shortest Cord Possible
− Stick Welding Smaw Guidelines
Stick Welding Procedure
Weld current starts when electrode touches work- piece
Striking an Arc − Tapping Technique
Electrode and Amperage Selection Chart
Striking an Arc − Scratch Start Technique
Positioning Electrode Holder
Poor Weld Bead Characteristics
Good Weld Bead Characteristics
10-30 9090
Conditions That Affect Weld Bead Shape
Electrode Movement During Welding
Tee Joint
Butt Joints
Lap Joint
Or Less
Weld Test
Troubleshooting − Porosity
Troubleshooting − Excessive Spatter
Possible Causes Corrective Actions
Troubleshooting − Excessive Penetration
Troubleshooting − Incomplete Fusion
Troubleshooting − Lack Of Penetration
Troubleshooting − Distortion
Troubleshooting − Burn-Through
Troubleshooting − Waviness Of Bead
− MIG Welding Gmaw Guidelines
Holding And Positioning Welding Gun
Slow Normal Fast
Push Perpendicular Drag
Short Normal Long
Gun Movement During Welding
15-9 Troubleshooting − Excessive Penetration
15-7 Troubleshooting − Excessive Spatter
15-8 Troubleshooting − Porosity
Improper joint preparation
Lack Of Penetration − shallow
Fusion between weld metal
Unsteady hand Support hand on solid surface or use two hands
Fillet
Common MIG Shielding Gases
Application
Page
Support
Service
Your distributor also gives
For assistance in filing or settling claims, contact
To locate a Distributor or Service Agency visit
Miller Electric Mfg. Co
Your distributor and/or equipment manufacturer’s
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