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Miller Electric Bobcat 250 User Manual

Miller Electric Bobcat 250
76 pages
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Bobcat 250
Processes
Description
Non-Critical TIG (GTAW)
Welding
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Engine Driven Welding Generator
OM-4419 211 392M
200705
Visit our website at
www.MillerWelds.com
File: Engine Drive

Table of Contents

Questions and Answers:

Miller Electric Bobcat 250 Specifications

General IconGeneral
BrandMiller Electric
ModelBobcat 250
CategoryWelding System
LanguageEnglish

Summary

Miller Bobcat 250

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-2. Arc Welding Hazards

Details hazards related to arc welding, including electric shock, hot parts, and flying metal.

FUMES AND GASES can be hazardous.

1-3. Engine Hazards

Using a generator indoors CAN KILL YOU IN MINUTES.

Critical warning about carbon monoxide poisoning from indoor generator use.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

1-6. California Proposition 65 Warnings

SECTION 5 – INSTALLATION

5-1. Installing Welding Generator

Provides instructions for safely installing the welding generator, including movement and grounding.

SECTION 6 – OPERATING THE WELDING GENERATOR

6-1. Front Panel Controls

Identifies and explains the functions of the front panel controls and switches.

6-3. Typical Stick Welding Connections And Control Settings

Details connections and settings for stick welding with various electrodes.

6-4. Typical MIG Welding Connections And Settings

Explains connections and settings for MIG welding with solid wire applications.

B. Self-Shielded Flux Core Wire Applications

Details connections and settings for self-shielded flux core wire MIG welding.

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun

Provides connections and settings for MIG welding using a weld control and spoolgun.

SECTION 8 – MAINTENANCE (ROBIN-POWERED UNITS)

8-1. Routine Maintenance (Robin-Powered Units)

Lists routine maintenance tasks for Robin-powered units based on operating hours.

8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)

Provides step-by-step instructions for changing engine oil, oil filter, and fuel filter.

SECTION 9 – MAINTENANCE – (KOHLER-POWERED UNITS)

9-1. Routine Maintenance (Kohler-Powered Units)

Lists routine maintenance tasks for Kohler-powered units based on operating hours.

9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)

Provides instructions for changing engine oil, oil filter, and fuel filter for Kohler-powered units.

SECTION 10 – TROUBLESHOOTING

10-1. Welding Troubleshooting

Lists common welding output problems and their potential causes and remedies.

10-2. Generator Power Troubleshooting

Lists common generator power output problems and their potential causes and remedies.

10-3. Engine Troubleshooting

Provides troubleshooting steps for engine starting, running, and idle issues.

SECTION 14 – STICK WELDING (SMAW) GUIDELINES

14-1. Stick Welding Procedure

Outlines the basic procedure for stick welding, including workpiece preparation and arc striking.

14-2. Electrode and Amperage Selection Chart

Provides a chart for selecting electrodes and amperage based on material and application.

14-3. Striking an Arc – Scratch Start Technique

Explains the scratch start technique for initiating a welding arc.

14-4. Striking an Arc – Tapping Technique

Explains the tapping technique for initiating a welding arc.

14-6. Poor Weld Bead Characteristics

Shows examples of common poor weld bead characteristics and their causes.

14-7. Good Weld Bead Characteristics

Displays examples of good weld bead characteristics and their attributes.

14-8. Conditions That Affect Weld Bead Shape

Explains how electrode angle, arc length, and travel speed impact weld bead shape.

14-14. Troubleshooting – Porosity

Identifies causes and corrective actions for porosity in weld metal.

14-15. Troubleshooting – Excessive Spatter

Lists causes and remedies for excessive spatter during welding.

14-16. Troubleshooting – Incomplete Fusion

Details causes and corrective actions for incomplete fusion in welds.

14-17. Troubleshooting – Lack Of Penetration

Explains causes and remedies for lack of penetration in welds.

14-18. Troubleshooting – Excessive Penetration

Identifies causes and corrective actions for excessive penetration in welds.

14-19. Troubleshooting – Burn-Through

Details causes and corrective actions for burn-through during welding.

14-20. Troubleshooting – Waviness Of Bead

Provides causes and remedies for waviness in the weld bead.

14-21. Troubleshooting – Distortion

Explains causes and corrective actions for distortion in welded parts.

SECTION 15 – MIG WELDING (GMAW) GUIDELINES

15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder

Shows typical connections for MIG welding with a voltage-sensing wire feeder.

15-2. Holding And Positioning Welding Gun

Illustrates proper gun holding and positioning techniques for MIG welding.

15-7. Troubleshooting – Excessive Spatter

Lists causes and remedies for excessive spatter in MIG welding.

15-8. Troubleshooting – Porosity

Details causes and corrective actions for porosity in MIG welds.

15-9. Troubleshooting – Excessive Penetration

Identifies causes and corrective actions for excessive penetration in MIG welds.

15-10. Troubleshooting – Lack Of Penetration

Explains causes and remedies for lack of penetration in MIG welds.

15-11. Troubleshooting – Incomplete Fusion

Lists causes and corrective actions for incomplete fusion in MIG welds.

15-12. Troubleshooting – Burn-Through

Details causes and corrective actions for burn-through in MIG welds.

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