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OM-4419 Page 5

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

If notified by the FCC about interference, stop using the

equipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere with

sensitive electronic equipment such as micro-

processors, computers, and computer-driven

equipment such as robots.

Be sure all equipment in the welding area is

electromagnetically compatible.

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Be sure this welding machine is installed and grounded

according to this manual.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,

 ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping,

 American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:

1-877-413-5184, website: www.global.ihs.com).

National Electrical Code,

 NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:

617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders,

 CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting,

 CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 5060 Mississauga,

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion,

 ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work,

 NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-

site: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.
To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from

operator as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding,  spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

Summary of Contents for Bobcat 250

Page 1: ...s Description Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 4419 211 392M 2007 05 Visit our website at www MillerWelds co...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...ions 12 4 2 Dimensions Weights and Operating Angles 13 4 3 Dimensions For Units With Optional Running Gear 13 4 4 Fuel Consumption Robin Powered Units 14 4 5 Fuel Consumption Kohler Powered Units 14 4...

Page 4: ...k 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 Re...

Page 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Page 6: ...ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire o...

Page 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Page 8: ...ge and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield t...

Page 9: ...tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Assoc...

Page 10: ...l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises da...

Page 11: ...provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pe...

Page 12: ...oquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et s...

Page 13: ...me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut...

Page 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Page 15: ...onal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standa...

Page 16: ...CTION 4 SPECIFICATIONS 4 1 Weld Power and Engine Specifications This unit uses either a Robin EH 65 or a Kohler CH 23 engine Differences between models are noted throughout this manual Welding Mode We...

Page 17: ...mm 4 Holes G tip C 1 3 4 in 44 mm E D 6 1 16 in 154 mm E F 25 E 32 3 4 in 832 mm 25 F 45 3 8 in 1153 mm 25 25 G 13 32 in 10 mm Dia 25 Weight Robin PoweredUnit 560 lb 254 kg Robin PoweredUnit 560 lb 25...

Page 18: ...about 20 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 3 4 gal lon per hour or about 16 hours of operation 4 5 Fuel Consumption Kohler Powered Units 220 181 On a typical...

Page 19: ...4 6 Volt Ampere Curves 200 296 200 297 200 298 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall b...

Page 20: ...nerator power curve shows the generator power in amperes available at the receptacles Continuous Welding 4 8 Duty Cycle 200 293 Duty cycle is the percentage of 10 minutes that unit can weld at rated l...

Page 21: ...Do not install unit where air flow is restricted or engine may overheat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Term...

Page 22: ...o monitor oil level Open top service door Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler neck empty to...

Page 23: ...oil level Open top service door Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler neck empty to allow roo...

Page 24: ...exhaust outlet Point exhaust pipe in desired direction but always away from front panel and direction of travel Be sure to tighten exhaust clamp nuts Exhaust clamp supplied with muffler Tools Needed...

Page 25: ...ly connect weld cables may cause exces sive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied n...

Page 26: ...0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2...

Page 27: ...Negative hours indicated when past rec ommendedoil change interval To reset cycle Engine Control switch from Run Idle to Run three times within five sec onds engine off 4 Weld Process Selector Switch...

Page 28: ...from piston ring blow by if the engine is exten sively idled This may cause vacuum line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in...

Page 29: ...cable to Elec trode terminal on welding generator Be sure to use the correct size weld cables see Section 5 7 For best performance set the Coarse Range switch to the low est range that covers the des...

Page 30: ...possible to drive rolls without touching Tighten knob See wire feeder manual for wire thread ing procedure Insert gun trigger plug item 4 into matching receptacle and tighten threaded collar Connect...

Page 31: ...t gun end through opening in feed er and position as close as possible to drive rolls without touching Tight en knob See wire feeder manual for wire threading procedure Insert gun trigger plug item 4...

Page 32: ...gger control plug item 11 into weld control receptacle Tighten threaded collar Connect ac power cord item 12 to 120 volt ac receptacle on welding generator Connect gas hose from spoolgun to regula tor...

Page 33: ...opens the receptacle does not work Press button to reset supplementary protector If supplementary protector continues to open contact Factory Authorized Service Agent 7 Optional 120 V 20 A AC GFCI Re...

Page 34: ...0 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2...

Page 35: ...fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 2 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 8 7 Spark Arrestor Scre...

Page 36: ...A complete Parts List is available at www MillerWelds com OM 4419 Page 32 8 2 Maintenance Label Robin Powered Units...

Page 37: ...Stop engine Disconnect negative battery cable 1 Fuse F1 See Section 11 1 F1 protects the weld excitation winding from overload If F1 opens weld output stops or is low 2 Fuse F2 See Section 11 1 F2 pr...

Page 38: ...r Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4...

Page 39: ...Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mou...

Page 40: ...ine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing 1 4 in 1 Tools Needed Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025...

Page 41: ...e engine fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 3 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 9 7 Spark Arre...

Page 42: ...A complete Parts List is available at www MillerWelds com OM 4419 Page 38 9 2 Maintenance Label Kohler Powered Units...

Page 43: ...engine with out air cleaner or with dirty element 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleane...

Page 44: ...ilter Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 5...

Page 45: ...on 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved...

Page 46: ...se F6 See Section 11 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating If a fuse opens it usually indi cat...

Page 47: ...ut Check control settings Check engine speed and adjust if necessary see Section 8 6 or 9 5 Erratic weld output Check control settings Tighten and clean connections to electrode and workpiece Use dry...

Page 48: ...Check low oil pressure shutdown switch Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 FS1 optional on Robin powered units Engine starts but stops when Engine Control switch retu...

Page 49: ...de icer product Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath er engine starts and goes to idl...

Page 50: ...OM 4419 Page 46 SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For Welding Generator...

Page 51: ...OM 4419 Page 47 228 460 A...

Page 52: ...ctric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Groun...

Page 53: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Page 54: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Page 55: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 56: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Page 57: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Page 58: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Page 59: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Secti...

Page 60: ...LET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 1...

Page 61: ...14 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 14 7 Good Weld Bead Characteristics...

Page 62: ...rrect Angle 14 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weav...

Page 63: ...4 14 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be f...

Page 64: ...Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface bef...

Page 65: ...dirt from work surface before welding 14 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Caus...

Page 66: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 14 21 Troubleshooting Distortion Distortion contraction of weld me...

Page 67: ...ptional gas valve Voltage Sensing Wire Feeder Constant Current CC Or Constant Voltage CV Power Source Work Lead Electrode Lead Workpiece Work Clamp Voltage Sensing Clamp Gun 802 488 15 2 Holding And P...

Page 68: ...lectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIO...

Page 69: ...Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 15 5 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Sligh...

Page 70: ...nsufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place noz...

Page 71: ...n Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pai...

Page 72: ...pport hand on solid surface or use two hands 15 14 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Page 73: ...uminum Short Circuiting Aluminum Argon All Positions5 All Positions Argon 1 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 2 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 5 O2 Fla...

Page 74: ......

Page 75: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 76: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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