Miller-electric Bobcat 250 User Manual

Bobcat 250ProcessesDescription™Non-Critical TIG (GTAW)WeldingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW) WeldingEngine Driven Welding Gene

OM-4419 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les

OM-4419 Page 7Une tension DC importante subsiste à l’intérieurdes onduleurs après avoir coupé l’alimentation. Couper l’alimentation du poste et décha

OM-4419 Page 8 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux à chaud et avoir de la surveillance et unextincteu

OM-4419 Page 9 Dévisser le bouchon légèrement et laisser la vapeur s’échapperavant d’enlever le bouchon.L’utilisation d’un groupe autonomeà l’intérie

OM-4419 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.

OM-4419 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 12SECTION 3 − DEFINITIONS3-1. Symbol DefinitionsStop EngineFast(Run, Weld/Powe

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 134-2. Dimensions, Weights, and Operating AnglesDimensionsHeight33-1/2 in (851

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 144-4. Fuel Consumption (Robin-Powered Units)220 571On a typical job using 1/8

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 154-6. Volt-Ampere Curves200 296 / 200 297 / 200 298The volt-ampere curve show

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 164-7. Generator Power Curve200 294The generator power curve showsthe generato

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 17SECTION 5 − INSTALLATIONinstall2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 185-2. Engine Prestart Checks (Robin-Powered Units)803 755-C / 217 015-AFullFu

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 195-3. Engine Prestart Checks (Kohler-Powered Units)803 754-C / 217 015-ACheck

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 205-4. Installing Exhaust Pipe803 751 / Ref. 228 201-B! Engine backfire can ca

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 21! Stop engine.1 Work Weld Output Terminal2 Electrode Weld Output TerminalCon

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 225-7. Selecting Weld Cable Sizes*Weld OutputTerminalsWeld Cable Size** and To

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 23SECTION 6 − OPERATING THE WELDING GENERATOR4366-1. Front Panel ControlsRef.

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 246-2. Cold Weather Engine OperationRef. 228 201-B1 Engine Control SwitchCarbu

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 25ELECTRODEDC*ACPOSITIONPENETRATIONUSAGEMIN. PREP, ROUGHHIGH SPATTERGENERALSMO

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usag

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 266-4. Typical MIG Welding Connections And SettingsA. Solid Wire Applications8

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 27B. Self-Shielded Flux Core Wire Applications803 750-B / 802 766 / 228 201-B!

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 286-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun802

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 29SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles803

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 307-2. Simultaneous Weld And PowerWeld Current in Amperes Total Power in Watts

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 31SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS)8-1. Routine Maintenance (Robin

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 328-2. Maintenance Label (Robin-Powered Units)

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 338-3. Servicing Air Cleaner (Robin-Powered Units) aircleaner3 11/04 − 803 0

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 348-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)8

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 358-6. Adjusting Engine Speed (Robin-Powered Units)803 755-C / 802 457After tu

TABLE OF CONTENTSSECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Rou

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 368-7. Servicing Optional Spark Arrestor (Robin-Powered Units)Ref. 801 682-A /

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 37SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)9-1. Routine Maintenance (Ko

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 389-2. Maintenance Label (Kohler-Powered Units)

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 399-3. Servicing Air Cleaner (Kohler−Powered Units) aircleaner3 11/04 − 802

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 409-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 419-5. Adjusting Engine Speed (Kohler-Powered Units)803 752 / 801 209-AAfter t

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 429-6. Overload Protection (Kohler-Powered Units)803 753-B! Stop engine. Disco

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 43SECTION 10 − TROUBLESHOOTING10-1. Welding TroubleshootingTrouble RemedyLow o

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 44Trouble RemedyLow power output at ac receptacles. Check fuse F2, and replace

 A complete Parts List is available at www.MillerWelds.comOM-4419 Page 45Trouble RemedyUnstable or sluggish engine speeds. Readjust throttle linkage

OM-4419 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions

OM-4419 Page 46SECTION 12 − ELECTRICAL DIAGRAMSFigure 12-1. Circuit Diagram For Welding Generator

OM-4419 Page 47228 460-A

OM-4419 Page 48SECTION 13 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4419 Page 4913-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4419 Page 5013-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4419 Page 5113-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4419 Page 5213-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4419 Page 5313-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4419 Page 5413-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4419 Page 55SECTION 14 − STICK WELDING (SMAW) GUIDELINES14-1. Stick Welding Procedurestick 2007−04 − ST-151 593! Weld current starts whenelectrode

OM-4419 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4419 Page 5614-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43

OM-4419 Page 5714-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode Angle

OM-4419 Page 5814-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, and thickness

OM-4419 Page 5914-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from draw-ing together ahead of electrode bytack welding the materials in po

OM-4419 Page 6014-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3

OM-4419 Page 6114-16. Troubleshooting − Incomplete FusionIncomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding w

OM-4419 Page 6214-19. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metal resultingin holes where no metal r

OM-4419 Page 63SECTION 15 − MIG WELDING (GMAW) GUIDELINES15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder! Weld current can d

OM-4419 Page 6415-3. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout)

OM-4419 Page 6515-4. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wi

OM-4419 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt

OM-4419 Page 6615-7. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead

OM-4419 Page 6715-10. Troubleshooting − Lack Of PenetrationLack Of Penetration − shallowfusion between weld metal andbase metal.Lack of Penetration Go

OM-4419 Page 6815-13. Troubleshooting − Waviness Of BeadWaviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base meta

OM-4419 Page 6915-15. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixture

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-4419 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4419 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni