Miller Electric Bobcat 225 Typical MIG Welding Connections And Settings, Solid Wire Applications

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

6-4. Typical MIG Welding Connections And Settings

A. Solid Wire Applications

! Stop engine.

Typical Control Settings For .035 (ER70S-3)

Solid Wire − Short Circuit Transfer

Note Coarse Range,

Fine Control, and

Weld Process switch

settings.

6

7

Quick connector

2

3

.This section provides general guide-

lines and may not suit all ap- plications.

.The control panel shows the typical

settings for welding with .035 (ER70S-3) solid wire. Use Argon- based shielding gas.

1Work Clamp

2Wire Feeder

3MIG Gun

4Gun Trigger Plug

5Voltage Sensing Clamp

6Gas Cylinder:

75/25 Argon-Based Gas for Short Circuit Transfer

80% Argon (Or Higher) For Spray Transfer

7Gas Hose

Connect work cable to welding generator Work terminal. Connect cable from wire feeder to cable from welding generator Electrode terminal.

.Be sure to use the correct size weld cables (see Section 5-7).

Loosen MIG gun securing knob. Insert gun end through opening in feeder and position as close as possible to drive rolls without touching. Tighten knob.

See wire feeder manual for wire thread- ing procedure.

Insert gun trigger plug (item 4) into matching receptacle and tighten threaded collar.

Connect gas hose from feeder to regula- tor on cylinder.

Typical Control Settings For Short

Circuit Transfer Using .035 (ER70S-3)

Solid Wire And 75/25 Argon-Based

Gas:

>Set Weld Process Selector switch to Wire + (DCEP) position.

>Set Coarse Range switch to Wire 19-28 volts position.

>Set Fine Control to obtain minimum spatter.

>Set wire feed speed between 150-300 ipm.

5 4

Work

1

Tools Needed: 3/4 in

803 847-C / 802 766 / 228 199-A

OM-4434 Page 27

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Contents File Engine Drive OM-4434From Miller to You Table of Contents 11-1 10-110-2 10-3HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine SpecificationsDimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Robin-PoweredUnit 560 lb 254 kgFuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered UnitsFor CC/DC Mode For CV/DC Mode For CC/AC ModeVolt-Ampere Curves Duty Cycle Generator Power CurveDo not use flexible mounts Grounding − InstallationInstalling Welding Generator MountingOil Check Engine Prestart Checks Robin-Powered UnitsOil Engine Prestart Checks Kohler-Powered Units Replacing The Battery Installing Exhaust PipeConnecting Or Replacing the Battery Connecting The Battery Connect negative − cable lastWork Weld Output Terminal Connecting to Weld Output TerminalsTools Needed Correct Installation Stop engine150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m OM-4434 − Operating the Welding Generator Engine Control SwitchPlace switch in Run position to operate most MIG equipment Coarse Range SwitchFrequently Loaded Cold Weather Engine OperationInfrequently LoadedElectrode Typical Stick Welding Connections And Control SettingsSolid Wire Applications Typical MIG Welding Connections And SettingsBe sure to use the correct size weld cables see Section Fine Control, Weld Process switch Settings Self-Shielded Flux Core Wire ApplicationsWork Typical Settings ForSet wire feed speed between 240-270 ipm OM-4434 MaterialStandard Receptacles − Operating Auxiliary EquipmentBreaker trips Optional Generator Power ReceptaclesReceptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240Maintenance Label Robin-Powered Units − Maintenance ROBIN-POWERED Units200 Routine Maintenance Robin-Powered UnitsStop engine before maintaining 100Servicing Optional Spark Arrestor Robin-Powered Units Servicing Air Cleaner Robin-Powered UnitsStop engine and let cool Oil Fill Close valve and valve capBefore adding oil Running engineWeld/Power Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsIdle Speed Adjustment Turn idle speed screw for fine adjustmentsStop engine. Disconnect negative − battery cable Overload Protection Robin-Powered UnitsMaintenance Label Kohler-Powered Units − Maintenance − KOHLER-POWERED UnitsHours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4434 Routine Maintenance Kohler-Powered UnitsServicing Air Cleaner Kohler−Powered Units 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveFull Before adding oil Running engine Turn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power TroubleshootingEngine Troubleshooting Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams228 461-A Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes− Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Holding And Positioning Welding Gun − MIG Welding Gmaw GuidelinesShort Normal Long Push Perpendicular DragSlow Normal Fast Gun Movement During Welding 15-8 Troubleshooting − Porosity 15-7 Troubleshooting − Excessive Spatter15-9 Troubleshooting − Excessive Penetration Fusion between weld metal Lack Of Penetration − shallowImproper joint preparation Base metal to move Unsteady hand Support hand on solid surface or use two handsApplication Common MIG Shielding GasesFillet Page Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. 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