OM-217 455H, File Engine Drive | Miller Electric 250 instruction

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OM-217 455H

2007−05−21

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Non-Critical TIG (GTAW)

Welding

Description

Engine Driven Welding Generator

Bobcat™ 250 Diesel

File: Engine Drive

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Miller Electric 250 manual OM-217 455H, File Engine Drive, Visit our website at, 2007−05−21

Contents

File Engine Drive OM-217 455HVisit our website at 2007−05−21 From Miller to You Table of Contents 13-3 13-213-4 13-5 Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burns Buildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosion Compressed Air Hazards Engine Hazards HOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injury California 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 spécifiques LES 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 DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicaux Symbol Definitions − SpecificationsWeld, Power, and Engine Specifications − Definitions Dimensions For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesDimensions Installing Welding Generator − InstallationVehicle frame. Always connect a ground wire Mounting Connecting the Battery Installing Exhaust Pipe+ − Stop engine and let cool Overview And Engine Prestart Checks Starting engine for the first time Engine Left Side Engine Right SideRun-in period first 100 hours Daily pre-start checks Correct Installation Connecting to Weld Output TerminalsWork Weld Output Terminal Tools Needed Do not place Selecting Weld Cable Sizes Place switch in Run position to operate most MIG equipment Engine Control Switches− Operating the Welding Generator Do not use glow plugs longer than 20 seconds Weld Output Controls Typical Settings For 7018 1/8 Electrode Typical Stick Welding Connections And Control SettingsStop engine Work Clamp Electrode Holder Set Weld Process Selector switch to Wire + Dcep position Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + position Set Weld Process Selector switch to Wire − position Dcen Tools Needed 3/4 Work Not Used To Work Left Side View − Operating Auxiliary Equipment Generator Power ReceptaclesAt least once a month, run engine at To verify Gfci is working properly Simultaneous Weld And Power Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current Battery Charge Cable Connections Minutes Battery Charging Procedure Start Your Professional Welding Career Now Routine Maintenance − Maintenance and Troubleshooting Stop engine and let cool Oil And Fuel Maintenance Label And Engine Maintenance Activities 804 197-A / Ref 803 111-A / 227 Ment is not covered by the warranty Cleaner or with dirty element. EngineAir cleaner primary element can Damage when determining whether Adjusting Fuel Solenoid Position Adjusting Engine SpeedStop screw is factory-set and should not be adjusted Checking Fuel Solenoid Checking Throttle Solenoid Adjusting Throttle Solenoid16 mm Check for non-binding Adjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Component Panel Stop engine Overload ProtectionFuse F1 Supplementary Protector CB8 Generator Power Troubleshooting TablesWelding Trouble Remedy Engine Maintenance Display Action Recommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1 Circuit Diagram For Welding Generator − Electrical Diagrams 228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and Wetstacking Fuel Consumption Curves − Performance DataUS Gal./Hr Idle Duty Cycle Generator Power CurveVolts AC Amperes At 120 Volts DC Amps CC/AC Stick Mode AC Volts Stick Mode Volt-Ampere CurvesAC Amps DC Amps MIG Mode Volt-Ampere Curve Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = Watts Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Weld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Electrode Movement During Welding Conditions That Affect Weld Bead Shape Lap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack Welds Troubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Work like a Pro Your distributor also gives ServiceSupport 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