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OM-258413 Page 48

SECTION 10 − ELECTRICAL DIAGRAMS

258 418-B

Figure 10-1. Circuit Diagram For Welder/Generator

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Summary of Contents for Bobcat 250 Diesel

Page 1: ...n Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welder Generator OM 258413H 2019 02 File Engine Drive For product information Owner s Manual trans...

Page 2: ...roducts continue 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 he...

Page 3: ...Definitions 14 SECTION 4 SPECIFICATIONS 17 4 1 Serial Number And Rating Label Location 17 4 2 Weld Power and Engine Specifications 17 4 3 Environmental Specifications 17 4 4 Dimensions Weights And Op...

Page 4: ...5 7 3 Simultaneous Weld And Power 36 7 4 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P 36 SECTION 8 MAINTENANCE AND TROUBLESHOOTING 37 8 1 Maintenance Label 37 8 2 Routine Ma...

Page 5: ...e wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental c...

Page 6: ...ent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side D Do not cut or weld on tire rims or w...

Page 7: ...period before working on equipment D To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn D If possible check...

Page 8: ...n D Do not touch hot compressor or air system parts D Allow cooling period before working on equipment D To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing t...

Page 9: ...ward any part of the body other people or any metal when threading welding wire OVERUSE can cause OVERHEATING D Allow cooling period follow rated duty cycle D Reduce current or reduce duty cycle befor...

Page 10: ...ndard 51B from National Fire Protection Association Quincy MA 02169 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Feder...

Page 11: ...s ou confin es ou s il y a un risque de chute D Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande D Si l utilisation d une source lectrique courant lect...

Page 12: ...es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort D Fermer l alimentation du gaz comprim en cas de non utilisation D Veiller toujours bien a r...

Page 13: ...de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne D Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branch...

Page 14: ...i est autoris installer utiliser et entretenir cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux D Ne pas d passer le d bit nominal ou...

Page 15: ...manuels d utilisateurs les normes nationales provinciales et de l industrie ainsi que les codes municipaux 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenan...

Page 16: ...pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT D Laisser l quipement refroidir respecter le fac teur de...

Page 17: ...2169 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indust ry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J...

Page 18: ...n dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 3 2 Miscellaneous Symbol Definitions A Amperage V Voltage X Duty Cycle U0 Rated No Lo...

Page 19: ...ge 15 Engine Oil Fuel Battery Engine Engine Engine Engine Start Engine RPM Engine Stop Glow Plug Air Filter Hour Meter Idle Slow Run Fast Belt Drive Temperature Call for Maintenance Check Valve Cleara...

Page 20: ...Complete Parts List is available at www MillerWelds com OM 258413 Page 16 Notes...

Page 21: ...Open Circuit Voltage Generator Power Rating Engine Liquids Capacity Engine CC AC 40 250 A 250 A 25 V 100 Duty Cycle 80 Peak 11 kVA kW Continuous 9 5 kVA kW Single Phase 80 40 A 120 240 V AC 60 Hz whi...

Page 22: ...18 4 4 Dimensions Weights And Operating Angles 259 701 259 702 Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip Weight 638 lb 289...

Page 23: ...E Exceeding duty cycle can damage unit and void warranty 1 4 6 Static Characteristics The static output characteristics of the welding power source can be described as flat during the GMAW process and...

Page 24: ...urs of operation per fuel fill Welding at 150 amps at 40 duty cycle uses approximately 1 2 gallon per hour or about 22 hours of operation per fuel fill 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 0 1...

Page 25: ...t where air flow is restricted or engine may over heat See Section 4 4 for lifting eye rat ing Mounting Do not mount unit by support ing the base only at the four mounting holes Do not use flexible mo...

Page 26: ...upport equipment 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or lar...

Page 27: ...llow the battery cables to touch opposing terminals When connect ing the battery cables attach the positive cable to the positive battery termin al first followed by negative cable to negative battery...

Page 28: ...7 2 Weld Output Terminals see Section 5 7 3 Operator Controls see Section 6 4 Fuel Gauge Maintenance Display 5 Fuel Filler Cap 6 Exhaust Pipe 7 Engine Maintenance Label 8 Radiator Cap 9 Water Bypass H...

Page 29: ...e S Running out of fuel air in fuel lines S Using gasoline S Using ether to start engine Engine stops if oil pressure is low engine coolant temperature is high or fuel level is low Some conditions may...

Page 30: ...x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger ca...

Page 31: ...le terminal and copper bar Make sure that the sur faces of the weld cable terminal and copper bar are clean 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 Weld Output Terminal 4 S...

Page 32: ...d In Run position engine runs at weld power speed Place switch in Run position to operate most MIG equipment 2 Glow Plug Switch If necessary push switch down before start up See glow plug table for op...

Page 33: ...TICE Do not switch while welding Use switch to select weld amperage range when Weld Process Selector switch is in Stick Tig position or voltage range when switch is in Wire position For best arc start...

Page 34: ...ings For 7018 1 8 in Electrode Set Weld Process Selector switch to Stick position Set Coarse Range switch to 60 160 1 8 position Set Fine control at 7 or higher for best results Consult the amperage s...

Page 35: ...20 28 Range position Set wire feed speed between 320 500 ipm Set Fine control to 3 and increase for longer arc length Typical Control Settings Using 045 E71T 11 Self Shielded Flux Core Wire Set Weld P...

Page 36: ...m For 1 4 in 6 mm and thicker materials set Coarse Range switch to Wire 20 28 and Fine Control to 6 In crease decrease Fine Control setting to increase decrease arc length 1 Weld Control 2 Spoolgun 3...

Page 37: ...Complete Parts List is available at www MillerWelds com OM 258413 Page 33 6 6 Fuel Hour Gauge Descriptions...

Page 38: ...ut put from RC2 or RC3 is 2 4 kVA kW Test GFCI monthly See Section 7 2 for GFCI information and for reset ting and testing procedures 3 Supplementary Protector CB1 CB1 protects receptacles RC1 RC2 and...

Page 39: ...s Reset and test GFCI receptacle according to the following procedures A solid green LED indicates power to the GFCI A solid red LED indicates that the GFCI has been tripped Resetting Testing GFCI Rec...

Page 40: ...ed for a 240 V 2 wire load or a 120 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 r...

Page 41: ...Complete Parts List is available at www MillerWelds com OM 258413 Page 37 SECTION 8 MAINTENANCE AND TROUBLESHOOTING 8 1 Maintenance Label...

Page 42: ...eplace Reference Every 8 Hours Section 5 5 n Coolant Level n Fuel Level n Oil Level Oil Fuel Spills Every 200 Hours Section 8 5 8 3 Engine Manual n Fuel Connections Z Oil Z Oil Filter l Air Cleaner n...

Page 43: ...y indicates a more serious problem exists Contact a Factory Authorized Service Agent 1 Fuse F1 F1 protects the weld excitation winding from overload If F1 opens weld output stops or is low 2 Fuse F2 F...

Page 44: ...manual Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up fuel Coolant 6 Radiator Cap 7 Radiator Drain Cock Located on bot tom of r...

Page 45: ...d check solenoid movement Checking Solenoid Off Position 1 Throttle Solenoid Plunger 2 Throttle Solenoid 3 Fuel Solenoid 4 Shutdown Lever 5 Shutdown Stop Screw 6 Fuel Solenoid Jam Nut 7 Shutdown Lever...

Page 46: ...sition Verify the vertical arm of the shutdown lever contacts or is within 1 16 in 1 5 mm of the adjustment screw housing If the shutdown lever does not contact the housing loosen the fuel solenoid ja...

Page 47: ...le lever Install link 5 8 in 16 mm on solenoid rod Reconnect link to shoulder bolt and throttle lever Push solenoid rod into idle ener gized position and check for non binding lateral movement of thro...

Page 48: ...sen jam nut While holding throttle link with a 3 8 in wrench turn plunger clock wise to increase idle speed or counter clockwise to decrease idle speed Tighten jam nut After adjusting idle speed verif...

Page 49: ...tions to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welder gener...

Page 50: ...anual and check fault indicators on fuel gauge see Section 6 1 Engine will not start if engine temperature is too high Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 a...

Page 51: ...aner element fuel oil filters 1 258349 Air Cleaner Intake Dry Straight Outlet 1 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 259934 Filter Fuel Kubota 1 187443 Oil Filter 1 187459 Belt Fan 1 GLO...

Page 52: ...OM 258413 Page 48 SECTION 10 ELECTRICAL DIAGRAMS 258 418 B Figure 10 1 Circuit Diagram For Welder Generator...

Page 53: ...OM 258413 Page 49 Notes...

Page 54: ...alth Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable fro...

Page 55: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approximatelysix times more power while starting the motor than when ru...

Page 56: ...e 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 Milk...

Page 57: ...00 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10 500 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 Cultivat...

Page 58: ...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 59: ...he electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same a...

Page 60: ...0 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 Use GFCI protection when operating auxiliary...

Page 61: ...ss current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 12 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc...

Page 62: ...LL 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 MED 12...

Page 63: ...o produce the best results hold a short arc travel at a uniform speed and feed the electrode downward at a constant rate as it melts 1 1 2 2 Groove Welds Fillet Welds 12 5 Poor Weld Bead Characteristi...

Page 64: ...oss gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wid...

Page 65: ...e good welds The single or double V groove weld is good for materials 3 16 3 4 in 5 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thic...

Page 66: ...ve 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 before welding Exce...

Page 67: ...e and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Se...

Page 68: ...se optional gas valve Voltage Sensing Wire Feeder Constant Current CC Or Constant Voltage CV Welding Power Source Work Lead Electrode Lead Workpiece Work Clamp Voltage Sensing Clamp Gun GMAW2 2018 12...

Page 69: ...hape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage 13 3 Conditions That Affect Weld Bead Shape Gun...

Page 70: ...Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 13 4 Gun Movement During Welding 13 5 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3...

Page 71: ...Insufficient 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 no...

Page 72: ...on 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 pa...

Page 73: ...ort hand on solid surface or use two hands 13 14 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the...

Page 74: ...W P Stainless Steel Spray Arc Aluminum Short Circuiting Aluminum GMAW P Aluminum Argon All Positions All Positions All Positions All Positions Argon 1 O2 Flat Horizontal Fillet All Positions Flat Hori...

Page 75: ...wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows GMAW Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder v...

Page 76: ...Notes...

Page 77: ...Notes...

Page 78: ...Notes...

Page 79: ...semblies TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Pa...

Page 80: ...h 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 Safety Equi...

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