Miller Electric 250

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

OM-217 455 Page 33

804 197-A / Ref 803 111-A / 227 727

Contents

Main Bobcat 250 Diesel Processes Description From Miller to You Page TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. BUILDUP OF GAS can injure or kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. NOISE can damage hearing. 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. HOT PARTS can cause severe burns. 1-5. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERHEATING can damage motors. FLYING SPARKS can cause injury. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Signification des symboles . 2-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation. DES PICES CHAUDES peuvent provoquer des brlures graves. e DES PIECES DE METAL ou DES SA- LETES peuvent provoquer des bles- sures dans les yeux. LES FUMES ET LES GAZ peuvent tr 2-3. Dangers existant en relation avec le moteur LEXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE. LE CARBURANT MOTEUR peut prov quer un incendie ou une explosion. DES ORGANES MOBILES peuvent pr o 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. LE SURCHAUFFEMENT peut endom- mager le moteur lectrique. LES TINCELLES VOLANTES ris- quent de provoquer des blessures. DES ORGANES MOBILES peuvent provoquer des blessures. LES FILS DE SOUDAGE peuvent provoquer des blessures. LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT. 2-6. Proposition californienne 65 Avertissements 2-7. Principales normes de scurit 2-8. Information EMF SECTION 3 DEFINITIONS h Hours s 3-1. Symbol Definitions SECTION 4 SPECIFICATIONS 4-1. Weld, Power, and Engine Specifications . 4-2. Dimensions, Weights, and Operating Angles ! B C 4-3. Dimensions For Units With Optional Running Gear SECTION 5 INSTALLATION ! 5-1. Installing Welding Generator ! 5-2. Installing Exhaust Pipe ! ! + 5-3. Connecting the Battery ! 5-4. Overview And Engine Prestart Checks ! Engine Left Side Engine Right Side . ! 5-5. Connecting to Weld Output Terminals 5-6. Selecting Weld Cable Sizes* ! Notes . SECTION 6 OPERATING THE WELDING GENERATOR 6-1. Engine Control Switches . Glow Plug Time 6-2. Weld Output Controls . 6-3. Typical Stick Welding Connections And Control Settings . > 6-4. Typical MIG Welding Connections And Settings . > 6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun . > SECTION 7 OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles ! . ! 7-2. Simultaneous Weld And Power 120 V AC 120 V AC Amperes 7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 240 V AC SECTION 8 OPERATING OPTIONAL BATTERY CHARGER 8-1. Battery Charge Controls 0500 1000 1500 2000 350 300 8-3. Battery Charge Cable Connections ! ! ! ! . 8-4. Battery Charging Procedure Notes SECTION 9 MAINTENANCE AND TROUBLESHOOTING 9-1. Routine Maintenance ! . 9-2. Maintenance Label And Engine Maintenance Activities ! Page 9-3. Servicing Air Cleaner . 9-4. Adjusting Engine Speed . A. Checking Fuel Solenoid . B. Checking Throttle Solenoid C. Making Engine Speed Adjustments . Tools Needed: 9-5. Overload Protection 9-6. Troubleshooting Tables A. Welding B. Generator Power C. Engine SECTION 10 PARTS LIST 10-1. Recommended Spare Parts . Page Page Page Page SECTION 12 RUN-IN AND WETSTACKING 12-1. Run-In And Wetstacking SECTION 13 PERFORMANCE DATA 13-1. Fuel Consumption Curves 13-2. Generator Power Curve 13-3. Duty Cycle 13-4. Stick Mode Volt-Ampere Curves 13-5. MIG Mode Volt-Ampere Curve SECTION 14 GENERATOR POWER GUIDELINES . 14-1. Selecting Equipment . ! . 14-3. Grounding When Supplying Building Systems . ! 14-4. How Much Power Does Equipment Require? 14-5. Approximate Power Requirements For Industrial Motors 14-6. Approximate Power Requirements For Farm/Home Equipment 14-7. Approximate Power Requirements For Contractor Equipment 14-8. Power Required To Start Motor 14-9. How Much Power Can Generator Supply? 14-10.Typical Connections To Supply Standby Power ! . 14-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 15 STICK WELDING (SMAW) GUIDELINES 15-1. Stick Welding Procedure ! OM-217 455 Page 59 15-2. Electrode and Amperage Selection Chart 2 3 15-3. Striking an Arc Scratch Start Technique 1 2 3 15-5. Positioning Electrode Holder 15-6. Poor Weld Bead Characteristics 15-7. Good Weld Bead Characteristics 15-8. Conditions That Affect Weld Bead Shape . 15-9. Electrode Movement During Welding . 15-10.Butt Joints 15-11.Lap Joint 15-12.Tee Joint 15-13.Weld Test 15-14.Troubleshooting Porosity 15-15.Troubleshooting Excessive Spatter 15-16.Troubleshooting Incomplete Fusion 15-17.Troubleshooting Lack Of Penetration 15-18.Troubleshooting Excessive Penetration 15-19.Troubleshooting Burn-Through 15-20.Troubleshooting Waviness Of Bead 15-21.Troubleshooting Distortion Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2007 (Equipment with a serial number preface of LH or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Owners Record