10-1, 10-2, 10-3, 11-1, 15-1, 15-2 | Miller Electric Bobcat 250

TABLE OF CONTENTS


SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS)			31
8-1.	Routine Maintenance (Robin-Powered Units)		31
8-2.	Maintenance Label (Robin-Powered Units)		32
8-3.	Servicing Air Cleaner (Robin-Powered Units)		33
8-4.	Overload Protection (Robin-Powered Units)		33
8-5.	Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)		34
8-6.	Adjusting Engine Speed (Robin-Powered Units)		35
8-7.	Servicing Optional Spark Arrestor (Robin-Powered Units)		36
SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)			37
9-1.	Routine Maintenance (Kohler-Powered Units)		37
9-2.	Maintenance Label (Kohler-Powered Units)		38
9-3.	Servicing Air Cleaner (Kohler−Powered Units)		39
9-4.	Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)		40
9-5.	Adjusting Engine Speed (Kohler-Powered Units)		41
9-6.	Overload Protection (Kohler-Powered Units)		42
9-7.	Servicing Optional Spark Arrestor (Kohler-Powered Units)		42
SECTION 10 − TROUBLESHOOTING			43
10-1.	Welding Troubleshooting		43
10-2.	Generator Power Troubleshooting		43
10-3.	Engine Troubleshooting		44
SECTION 11 − PARTS LIST			45
11-1.	Recommended Spare Parts		45
SECTION 12 − ELECTRICAL DIAGRAMS			46
SECTION 13 − GENERATOR POWER GUIDELINES			48
SECTION 14 − STICK WELDING (SMAW) GUIDELINES			55
SECTION 15 − MIG WELDING (GMAW) GUIDELINES			63
15-1.	Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder		63
15-2.	Holding And Positioning Welding Gun		63
15-3.	Conditions That Affect Weld Bead Shape		64
15-4.	Gun Movement During Welding		65
15-5.	Poor Weld Bead Characteristics		65
15-6.	Good Weld Bead Characteristics		65
15-7.	Troubleshooting − Excessive Spatter		66
15-8.	Troubleshooting − Porosity		66
15-9.	Troubleshooting − Excessive Penetration		66
15-10.		Troubleshooting − Lack Of Penetration	67
15-11.		Troubleshooting − Incomplete Fusion	67
15-12.		Troubleshooting − Burn-Through	67
15-13. Troubleshooting − Waviness Of Bead			68
15-14.		Troubleshooting − Distortion	68
15-15.		Common MIG Shielding Gases	69

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Miller Electric Bobcat 250 10-1, 10-2, 10-3, 11-1, 15-2, 15-3, 15-4, 15-5, 15-6, 15-7, 15-8, 15-9, 15-10, 15-11, 15-12

Contents

OM-4419 File Engine DriveVisit our website at 2007−05 From Miller to You Table of Contents 10-1 10-210-3 11-1 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN 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 LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − Definitions Dimensions, Weights, and Operating Angles Dimensions For Units With Optional Running GearRobin-PoweredUnit 560 lb 254 kg Dimensions Fuel Consumption Robin-Powered Units Fuel Consumption Kohler-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 − Installation Installing Welding Generator Engine Prestart Checks Robin-Powered Units 0000Oil Check Oil Engine Prestart Checks Kohler-Powered Units Open top service door Installing Exhaust Pipe Connecting Or Replacing the BatteryConnecting The Battery Connect negative − cable last + − Connecting to Weld Output Terminals Tools Needed Correct InstallationStop engine Work Weld Output Terminal Selecting Weld Cable Sizes − Operating the Welding Generator Front Panel Controls Cold Weather Engine Operation InfrequentlyLoaded Frequently Loaded Typical Stick Welding Connections And Control Settings Typical Settings For 7018 1/8 in ElectrodeWork Clamp Electrode Holder Tools Needed 3/4 Typical MIG Welding Connections And Settings Solid Wire ApplicationsFine Control, Weld Process switch Settings Quick connector Be sure to use the correct size weld cables see Section Self-Shielded Flux Core Wire Applications Fine Control, Weld Process switch Settings Typical Settings For 4043 Aluminum On 1/8 in MaterialWork Lines and may not suit all applications Cables see Section Generator Power Receptacles − Operating Auxiliary Equipment Simultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle Routine Maintenance Robin-Powered Units 100200 500 Maintenance Label Robin-Powered Units Overload Protection Robin-Powered Units Servicing Air Cleaner Robin-Powered UnitsStop engine. Disconnect negative − battery cable Oil Fill Oil Check FullStop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil Filter Adjusting Engine Speed Robin-Powered Units Idle Speed AdjustmentTurn idle speed screw for fine adjustments 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 Stop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterClose valve and valve cap before adding oil Full 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 − Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble Remedy Check receptacle wiring and connections Engine TroubleshootingCheck fuel level − Parts List Switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts − Electrical Diagrams Circuit Diagram For Welding Generator 228 460-A − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond Generator Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = Watts Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-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 Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint Or Less Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion − MIG Welding Gmaw Guidelines Holding And Positioning Welding Gun 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 To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s