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Bobcat 250 NT
Miller Bobcat 250 NT User Manual
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Bobcat
250
NT
Processes
Description
Non-Critical
TIG (GT
AW)
W
elding
Stick (SMA
W) W
elding
MIG (GMA
W) W
elding
Flux Cored (FCA
W) Welding
Engine Driven Welding Generator
OM-4403
200 291E
April 2002
Visit our website at
www.MillerWelds.com
2
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 – Safety Precautions - Read before Using
5
Symbol Usage
5
Arc Welding Hazards
5
Engine Hazards
6
Additional Symbols for Installation, Operation, and Maintenance
7
Emf Information
8
Principal Safety Standards
8
Signification des Symboles
9
Dangers Relatifs Au Soudage À L'arc
9
Dangers Existant en Relation Avec Le Moteur
10
Dangers Supplémentaires en Relation Avec L'installation, Le Fonctionnement
11
Et la Maintenance
11
Principales Normes de Sécurit
12
Information Sur Les Champs Électromagnétiques
12
Symbol Definitions
13
Specifications
13
Section 2 – Definitions
13
Weld, Power, and Engine Specifications
13
Dimensions, Weights, and Operating Angles
14
Generator Power Curve
14
Volt-Ampere Curves
16
Section 4 – Installation
17
Duty Cycle
17
Installing Welding Generator
17
Engine Prestart Checks (Onan-Powered Units)
18
Engine Prestart Checks (Kohler-Powered Units)
19
Activating the Dry Charge Battery (if Applicable)
20
Connecting the Battery
21
Installing Exhaust Pipe
21
Connecting to Weld Output Terminals
22
Selecting Weld Cable Sizes
22
Section 5 – Operating the Welding Generator
23
Front Panel Controls
23
Typical Stick Welding Connections and Control Settings
24
Typical Mig Welding Connections and Settings
25
Typical Mig Connections and Settings Using Weld Control and Spoolgun
27
Section 6 – Operating Auxiliary Equipment
28
Standard Receptacles
28
Optional Generator Power Receptacles
29
Section 7 – Maintenance (Onan-Powered Units)
30
Wiring Optional 240 Volt Plug
30
Routine Maintenance (Onan-Powered Units)
30
Maintenance Label (Onan-Powered Units)
32
Servicing Air Cleaner (Onan-Powered Units)
33
Overload Protection (Onan-Powered Units)
33
Changing Engine Oil, Oil Filter, and Fuel Filter (Onan-Powered Units)
34
Adjusting Engine Speed (Onan-Powered Units)
35
Section 8 – Maintenance – (Kohler-Powered Units)
36
Servicing Optional Spark Arrestor (Onan-Powered Units)
36
Routine Maintenance (Kohler-Powered Units)
36
Maintenance Label (Kohler-Powered Units)
38
Servicing Air Cleaner (Kohler-Powered Units)
38
Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)
39
Adjusting Engine Speed (Kohler-Powered Units)
40
Overload Protection (Kohler-Powered Units)
41
Servicing Optional Spark Arrestor (Kohler-Powered Units)
41
Generator Power Troubleshooting
42
Section 9 - Troubleshooting
42
Welding Troubleshooting
42
Engine Troubleshooting
43
Section 10 - Electrical Diagrams
46
Grounding Generator to Truck or Trailer Frame
48
Section 11 - Generator Power Guidelines
48
Section 12 - Stick Welding (Smaw) Guidelines
55
Section 13 - Mig Welding (Gmaw) Guidelines
63
Typical MIG Process Connections Using a Voltage-Sensing Wire Feeder
63
Typical MIG Process Connections Using a Constant Speed Wire Feeder
63
Typical MIG Process Control Settings
64
Holding and Positioning Welding Gun
65
Conditions that Affect Weld Bead Shape
66
Gun Movement During Welding
67
Poor Weld Bead Characteristics
67
Good Weld Bead Characteristics
67
Troubleshooting - Excessive Spatter
68
Troubleshooting - Porosity
68
Troubleshooting - Excessive Penetration
68
Troubleshooting - Lack of Penetration
69
Troubleshooting - Incomplete Fusion
69
Troubleshooting - Burn-Through
69
Troubleshooting - Waviness of Bead
70
Troubleshooting - Distortion
70
Common MIG Shielding Gases
71
Section 14 - Parts List
72
Options and Accessories
80
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Miller Bobcat 250 NT Specifications
General
Input Voltage
120/240 V
Fuel Type
Gasoline
Duty Cycle
100%
Frequency
60 Hz
Noise Level
68 dBA at 7 m
Input Phase
1-Phase
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