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Miller Electric Comprehensive Troubleshooting Guide for Bobcat 250 Welding Systems

Models: Bobcat 250

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228 460-A

OM-4419 Page 47

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Miller Electric Bobcat 250 manual 228 460-A

Contents

2007−05 OM-4419File Engine Drive Visit our website at From Miller to You Table of Contents 11-1 10-110-2 10-3 HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque 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 blessures En ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine Specifications Dimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Robin-PoweredUnit 560 lb 254 kg Fuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered Units For CC/AC Mode For CC/DC Mode For CV/DC ModeVolt-Ampere Curves Generator Power Curve Duty Cycle100% Duty Cycle at 250 Amperes Installing Welding Generator − Installation Oil Engine Prestart Checks Robin-Powered Units0000 Oil Check Open top service door Engine Prestart Checks Kohler-Powered Units + − Installing Exhaust PipeConnecting Or Replacing the Battery Connecting The Battery Connect negative − cable last Work Weld Output Terminal Connecting to Weld Output TerminalsTools Needed Correct Installation Stop engine Selecting Weld Cable Sizes Front Panel Controls − Operating the Welding Generator Frequently Loaded Cold Weather Engine OperationInfrequently Loaded Tools Needed 3/4 Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 in Electrode Work Clamp Electrode Holder Be sure to use the correct size weld cables see Section Typical MIG Welding Connections And SettingsSolid Wire Applications Fine Control, Weld Process switch Settings Quick connector Fine Control, Weld Process switch Settings Self-Shielded Flux Core Wire Applications Lines and may not suit all applications Cables see Section Typical Settings For 4043Aluminum On 1/8 in Material Work − Operating Auxiliary Equipment Generator Power Receptacles Receptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240 500 Routine Maintenance Robin-Powered Units100 200 Maintenance Label Robin-Powered Units Servicing Air Cleaner Robin-Powered Units Overload Protection Robin-Powered UnitsStop engine. Disconnect negative − battery cable Oil Drain Valve 2 ID x 7 in Hose Oil Filter Oil Fill Oil CheckFull Stop engine and let cool Weld/Power Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsIdle Speed Adjustment Turn idle speed screw for fine adjustments 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 Up fuel Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Close valve and valve cap before adding oil Full 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 Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power Troubleshooting Engine Troubleshooting Check receptacle wiring and connectionsCheck fuel level Recommended Spare Parts − Parts ListSwitch S2, and throttle solenoid TS1 Recommended Spare Parts Circuit Diagram For Welding Generator − Electrical Diagrams 228 460-A Electrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Farm/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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique 10-30 9090 Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape Or Less Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Holding And Positioning Welding Gun − MIG Welding Gmaw Guidelines Push Perpendicular Drag Short Normal LongSlow Normal Fast Gun Movement During Welding 15-7 Troubleshooting − Excessive Spatter 15-8 Troubleshooting − Porosity15-9 Troubleshooting − Excessive Penetration Lack Of Penetration − shallow Fusion between weld metalImproper joint preparation Unsteady hand Support hand on solid surface or use two hands Common MIG Shielding Gases ApplicationFillet Page Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. 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