Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Bobcat 250 manual OM-4419, File Engine Drive, Visit our website at, 2007−05

Models: Bobcat 250

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OM-4419	211 392M
2007−05

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Non-Critical TIG (GTAW)

Welding

Description

Engine Driven Welding Generator

Bobcat™ 250

File: Engine Drive

Page 1

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Miller Electric Bobcat 250 manual OM-4419, File Engine Drive, Visit our website at, 2007−05

Contents

File Engine Drive OM-4419Visit our website at 2007−05 From Miller to You Table of Contents 10-2 10-110-3 11-1 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 AnglesRobin-PoweredUnit 560 lb 254 kg Dimensions Fuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered Units For CC/DC Mode For CV/DC Mode For CC/AC ModeVolt-Ampere Curves Duty Cycle Generator Power Curve100% Duty Cycle at 250 Amperes Installing Welding Generator − Installation 0000 Engine Prestart Checks Robin-Powered UnitsOil Check Oil Open top service door Engine Prestart Checks Kohler-Powered Units Connecting 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 Terminal Selecting Weld Cable Sizes Front Panel Controls − Operating the Welding Generator Infrequently Cold Weather Engine OperationLoaded Frequently Loaded Typical Settings For 7018 1/8 in Electrode Typical Stick Welding Connections And Control SettingsWork Clamp Electrode Holder Tools Needed 3/4 Solid 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 Section Fine Control, Weld Process switch Settings Self-Shielded Flux Core Wire Applications Aluminum On 1/8 in Material Typical Settings For 4043Work Lines and may not suit all applications Cables see Section − Operating Auxiliary Equipment Generator Power Receptacles Wiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 Receptacle 100 Routine Maintenance Robin-Powered Units200 500 Maintenance Label Robin-Powered Units Overload Protection Robin-Powered Units Servicing Air Cleaner Robin-Powered UnitsStop engine. Disconnect negative − battery cable Full Oil Fill Oil CheckStop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil Filter Idle Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsTurn idle speed screw for fine adjustments Weld/Power Speed Adjustment Material Thickness Reference Chart Servicing Optional Spark Arrestor Robin-Powered Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4419 Routine Maintenance Kohler-Powered Units Maintenance 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 fuel Turn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered Units Welding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble Remedy Check receptacle wiring and connections Engine TroubleshootingCheck fuel level Switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare Parts Circuit Diagram For Welding Generator − Electrical Diagrams 228 460-A Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Electrically Bond Generator 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 Electrode Movement During Welding Conditions That Affect Weld Bead Shape Lap Joint Butt JointsTee Joint Or Less 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 Holding And Positioning Welding Gun − MIG Welding Gmaw Guidelines Short 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 Unsteady hand Support hand on solid surface or use two hands Application Common MIG Shielding GasesFillet Page 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