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Miller Bobcat 200 Air Pak User Manual

Miller Bobcat 200 Air Pak
84 pages
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OM-283762A 2019-03
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Engine Drive
t
Bobcat 200 Air Pak
Processes
Description
Engine Driven Air Compressor,
Generator, Battery Charger, And
Welder
Battery Charging
Multiprocess Welding

Table of Contents

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Miller Bobcat 200 Air Pak Specifications

General IconGeneral
Engine Power23 HP
Fuel Tank Capacity12 Gallons
Engine TypeKohler Command Pro
Open-Circuit Voltage (OCV)80 Volts
EngineKohler CH740
AC Generator Output120/240 Volts
Auxiliary Power7, 000 Watts Continuous

Summary

Safety Precautions

Symbol Usage

Explains the meaning of symbols used in the manual to indicate hazards and warnings.

Arc Welding Hazards

Details potential hazards associated with arc welding, including electric shock and proper procedures.

Engine Hazards

Covers hazards related to the engine, such as battery explosion, fuel risks, and moving parts.

Compressed Air Hazards

Highlights dangers associated with compressed air equipment, including injury and death risks.

Additional Safety Symbols

Defines symbols related to fire, explosion, falling equipment, and overheating hazards.

California Proposition 65 Warnings

Provides warnings about chemical exposures from the product and diesel engines.

Principal Safety Standards

Lists relevant industry safety standards and where to obtain them.

EMF Information

Explains electromagnetic fields (EMF) and their potential interference with medical implants.

Specifications

Serial Number and Rating Label Location

Identifies the location of the product's serial and rating information.

Air Compressor Specifications

Details the performance and capacity of the air compressor.

Battery Charger Specifications

Outlines the output and voltage capabilities of the battery charger.

Power and Engine Specifications

Provides details on generator power rating, fuel capacity, and engine type.

Weld Specifications

Lists rated welding output and voltage ranges for different welding modes.

Environmental Specifications

Specifies the IP rating and intended use environment for the equipment.

Temperature Specifications

Defines the operating and storage temperature ranges for the unit.

Dimensions, Weights, and Operating Angles

Provides physical measurements, weight, and tilt angle limitations.

Duty Cycle and Overheating

Explains duty cycle percentages at different amperages and overheating precautions.

Generator Power Curves

Illustrates generator power output in amperes for 120V and 240V loads.

Volt-Ampere Curves - Weld

Shows minimum and maximum voltage/amperage capabilities for welding processes.

Volt-Ampere Curves - Battery Charge

Displays voltage and amperage curves for battery charging operations.

Fuel Consumption

Provides graphs showing fuel consumption for air compressor, auxiliary power, and welding.

Installation

Installing Unit

Provides guidance on unit placement, movement, and airflow clearance requirements.

Grounding Generator to Truck or Trailer Frame

Details the procedure for grounding the generator frame to a vehicle frame for safety.

Air Compressor Connections

Explains how to connect the air compressor, including hose requirements and fittings.

Engine Prestart Checks

Outlines essential checks for the engine before starting, including fluids and fuel.

Compressor Prestart Checks

Details pre-operation checks for the compressor, focusing on oil level and air cleaner.

Connecting The Battery

Provides instructions for correctly connecting the unit's battery.

Installing Exhaust Pipe

Guides on installing the exhaust pipe, including proper direction and clamping.

Connecting External Fuel Supply

Explains how to connect an external fuel supply, including hose routing and filling.

Controls

Control Panel Overview

Identifies and describes the main components and indicators on the control panel.

Control Panel Details (Continued)

Provides further descriptions of control panel functions and indicators.

Process/Contactor Switch

Explains the function of the process switch for selecting welding or battery charge modes.

Service Menu

Details how to access and navigate the service menu for settings and diagnostics.

Software Updates

Provides instructions on how to update the unit's software using a USB drive.

Summary File

Explains how to access and interpret the summary file for diagnostic information.

Fuel/Hour Gauge Descriptions

Describes the function and display of the fuel gauge and hour meter.

Compressor System Operation

Air Compressor Switch

Explains the function of the compressor switch for selecting CFM output and operation modes.

Air Compressor Controls and Pressure Adjustment

Details the controls for adjusting system pressure and the compressor's idle/standby modes.

Air Compressor Operation With Air Tools

Provides guidance on operating the air compressor with various air tools.

Battery Charging and Jump-Starting

Battery Charging Guidelines

Lists important guidelines and precautions for charging and jump-starting batteries.

Connecting Uninstalled Battery

Provides step-by-step instructions for connecting an external battery for charging.

Connecting Installed Battery

Details how to connect a vehicle's installed battery for charging or jump-starting.

Setting Battery Charge Controls

Explains how to set the controls for battery charging operations.

Battery Jump/Crank Assist Controls

Details how to set controls for jump-starting or crank-assisting a vehicle.

Display Screens for Battery Charging

Explains the information displayed on the screens during battery charging.

Operating Auxiliary Equipment

Generator Power Receptacles

Identifies the power receptacles and supplementary protectors on the generator.

GFCI Receptacle Usage and Testing

Provides information on GFCI receptacles, including testing and resetting procedures.

Wiring for 240 Volt Plug

Details wiring instructions for the optional 240 Volt, single-phase plug (NEMA 14-50P).

Welding Operation

Selecting Weld Cables

Provides a chart for selecting appropriate weld cable sizes based on length and duty cycle.

Weld Output Terminals

Identifies the positive and negative weld output terminals on the machine.

Connecting Weld Output Cables

Explains the correct procedure for connecting weld output cables to the terminals.

Weld Controls Overview

Identifies the main controls used for welding operations.

Arc Control Settings

Details arc control settings for different welding processes and their effects.

Stick Welding Start Procedure

Describes the scratch start technique for initiating a welding arc with stick electrodes.

Lift-Arc TIG Operation

Explains the Lift-Arc TIG process for starting an arc and using Auto-Stop.

MIG Welding Setup

Provides guidelines for MIG welding connections, settings, and gas requirements.

Connecting Spool Gun

Details the connections required for using a spool gun accessory.

Maintenance and Troubleshooting

Maintenance Schedule

Provides a maintenance schedule based on operating hours and time intervals.

Routine Maintenance Tasks

Outlines regular maintenance activities like checking fluids, filters, and belts.

Changing Compressor Fluids and Filters

Details the process for changing compressor oil, oil filter, and air cleaner element.

Servicing Air Cleaner

Explains how to clean and service the air cleaner element and pre-cleaner.

Changing Engine Fluids and Filters

Provides instructions for changing engine oil, oil filter, and fuel filter.

Overload Protection

Describes the overload protection devices (circuit breakers, protectors) and their function.

Error Displays and Diagnostics

Lists common error displays and their descriptions, remedies, and troubleshooting steps.

Troubleshooting Compressor Issues

Provides solutions for common problems related to the air compressor's operation.

Parts List

Recommended Spare Parts

Lists part numbers and descriptions for recommended spare parts.

Diagrams

Generator Power Guidelines

Selecting Equipment for Generator Use

Guidance on selecting appropriate equipment to connect to the generator.

Grounding Generator to Vehicle Frame

Details on grounding the generator frame to a vehicle for electrical safety.

Grounding for Building Systems

Instructions for grounding the generator when supplying power to building systems.

Calculating Equipment Power Requirements

Explains how to calculate power needs for various equipment using volts and amperes.

Power Requirements for Various Motors

Provides approximate power requirements for different types and sizes of industrial motors.

Power Requirements for Farm/Home Equipment

Lists approximate power requirements for common farm and home equipment.

Power Requirements for Contractor Equipment

Provides approximate power requirements for various contractor tools and equipment.

Motor Starting Power Needs

Details the starting amperage requirements for single-phase induction motors.

Generator Power Supply Capacity

Explains how to determine the generator's power supply capacity and load management.

Standby Power Connections

Illustrates typical connections for supplying standby power during outages.

Selecting Extension Cords

Guides on selecting appropriate extension cords based on load, length, and conductor size.

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