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1-800-4-A-MILLER

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Miller distributor.

miller_warr 2007

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Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY 

 Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.
1.

5 Years Parts — 3 Years Labor

* Original main power rectifiers

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3.

1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue

®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4.

6 Months — Batteries

5.

90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

* Induction 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

Miller’s True Blue

®

 Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2.

Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.
In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

 

Содержание Bobcat 250

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 74: ......

Страница 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...

Страница 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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