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Miller Bobcat 265X User Manual

Miller Bobcat 265X
80 pages
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OWNER’S MANUAL
OM-291417E
2023-11
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welder/Generator
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
Bobcat
265X

Table of Contents

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Miller Bobcat 265X Specifications

General IconGeneral
Rated Output9, 500 Watts
Fuel TypeGasoline
TypeEngine-Driven Welder/Generator
Open Circuit Voltage80 VDC
AC Output120/240V
Voltage Output120/240 VAC
EngineKohler

Summary

Safety Precautions

Symbol Usage

Explains the meaning of safety symbols used throughout the manual.

Arc Welding Hazards

Details hazards associated with arc welding processes and protective measures.

Engine Hazards

Outlines potential dangers related to the engine and its components.

Compressed Air Hazards

Covers hazards related to compressed air equipment and its use.

Additional Hazards For Installation, Operation, And Maintenance

Addresses further hazards during installation, operation, and maintenance.

California Proposition 65 Warnings

Provides chemical exposure warnings as required by California law.

Principal Safety Standards

Lists key safety standards and their sources for reference.

EMF Information

Explains electromagnetic field effects and precautions for users.

Definitions

Additional Safety Symbol Definitions

Defines additional safety symbols, potentially for specific product versions.

Miscellaneous Symbol Definitions

Provides definitions for miscellaneous symbols used in the manual.

Specifications

Serial Number And Rating Label Location

Details the location of serial and rating labels for product identification.

Software Licensing Agreement

Outlines the end-user license agreement for included software.

Information About Default Weld Parameters And Settings

Discusses default weld parameters and the need for user evaluation.

Weld, Power, And Carbureted Engine Specifications

Lists detailed specifications for welding output, power, and engine.

Environmental Specifications

Details IP rating and temperature specifications for operation and storage.

A. IP Rating

Specifies the Ingress Protection (IP) rating of the equipment.

B. Temperature Specifications

Details operating and storage temperature ranges for the unit.

Base Unit Dimensions, Weights, And Operating Angles

Provides physical dimensions, weight, and operating angle limits of the unit.

Dimensions For Units With Optional Running Gear

Lists dimensions for units equipped with optional running gear.

Duty Cycle And Overheating

Explains duty cycle ratings and the risks of overheating the unit.

Volt-Ampere Curves

Shows output capabilities of the welding generator across different amperage settings.

Fuel Consumption

Details fuel usage rates for auxiliary power and welding loads.

Installation

Installing Welder/Generator

Provides instructions and safety precautions for mounting and positioning the unit.

Grounding Generator to Truck or Trailer Frame

Details how to properly ground the generator frame to a vehicle frame.

Ground Cable Routing

Guides on routing the ground cable securely and correctly.

Installing Exhaust Pipe

Instructions for installing the exhaust pipe, including safety considerations.

Engine Prestart Checks

Outlines necessary checks for the engine before starting it.

Connecting Or Replacing The Battery

Explains the correct procedure for connecting or replacing the unit's battery.

Weld Output Terminals

Identifies and describes the weld output terminals on the unit.

Connecting Weld Output Cables

Details the correct method for connecting weld output cables to terminals.

Selecting Cable Sizes*

Provides guidelines for selecting appropriate weld cable sizes based on current and length.

Operation

Dial Front Panel Controls

Describes the function of each control on the front panel of the unit.

Fuel/Hour Gauge Descriptions

Explains the fuel gauge, hour meter, and oil change indicators.

Typical Stick Welding Connections And Control Settings

Provides typical connections and settings for Stick (SMAW) welding.

Typical MIG Welding Connections and Settings

Details typical connections and settings for MIG (GMAW) welding.

A. Solid Wire Applications

Covers setup and parameters for solid wire MIG welding applications.

B. Self-Shielded Flux Core Wire Applications

Details setup and parameters for self-shielded flux core MIG welding.

Cold Weather Engine Operation

Offers guidance on operating the engine in cold weather conditions.

Operating Auxiliary Equipment

Generator Power Receptacles

Identifies and describes the available generator power receptacles.

GFCI Receptacle Information, Resetting, And Testing

Explains GFCI receptacle functions, testing, and resetting procedures.

Simultaneous Weld And Power

Discusses power output distribution when welding and using auxiliary power.

Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 14-50P)

Provides instructions for wiring a 240V, single-phase NEMA 14-50P plug.

Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P)

Provides instructions for wiring a 240V, single-phase NEMA 6-50P plug.

Maintenance And Troubleshooting

Routine Maintenance

Presents a maintenance schedule for regular checks and servicing.

Maintenance Label

Details the information found on the machine's maintenance label.

Servicing Air Cleaner

Provides instructions for cleaning or replacing the air cleaner element.

Overload Protection

Explains the overload protection system, including fuse F6.

Changing Engine Oil, Oil Filter, And Fuel Filter

Details the procedure for changing engine oil, oil filter, and fuel filter.

Adjusting Engine Speed

Guides on adjusting engine idle and weld/power speeds.

Servicing Optional Spark Arrestor

Instructions for cleaning and inspecting the optional spark arrestor.

Fault Indicator

Explains the meaning of the fault indicator light and its possible causes.

Troubleshooting

A comprehensive guide to diagnosing and resolving welding and generator issues.

A. Welding Troubleshooting

Guides on diagnosing and resolving welding-related problems.

B. Generator Power Troubleshooting

Guides on diagnosing and resolving generator power output issues.

C. Engine Troubleshooting

Guides on diagnosing and resolving engine-related problems.

Parts List

Recommended Spare Parts

Lists recommended spare parts with their part numbers and descriptions.

Electrical Diagrams

Circuit Diagram

Presents the main electrical circuit diagram for the unit.

Generator Power Guidelines

Selecting Equipment

Advises on selecting suitable electrical equipment to connect to the generator.

Grounding When Supplying Building Systems

Explains grounding procedures when supplying power to building systems.

How Much Power Does Equipment Require?

Helps users determine the power requirements of their equipment.

Approximate Power Requirements For Industrial Motors

Provides power requirements for various industrial motors.

Approximate Power Requirements For Farm/Shop Equipment

Lists approximate power needs for farm and shop equipment.

Approximate Power Requirements For Contractor Equipment

Details power requirements for common contractor equipment.

Power Required To Start Motor

Explains how to calculate the power needed for starting motors.

How Much Power Can Generator Supply?

Guides on how to manage loads to not exceed the generator's capacity.

Typical Connections To Standby Power

Illustrates typical connections for using the generator with standby power systems.

Selecting Extension Cord (Use Shortest Cord Possible)

Provides tables for selecting appropriate extension cords based on length and load.

A. Cord Lengths For 120 Volt Loads

Offers guidance on selecting extension cord lengths for 120V loads.

B. Cord Lengths For 240 Volt Loads

Offers guidance on selecting extension cord lengths for 240V loads.

Stick Welding (SMAW) Guidelines

Stick Welding Procedure

Outlines the basic steps and tools needed for stick welding.

Electrode And Amperage Selection Chart

Helps select the correct electrode and amperage for different welding tasks.

Striking An Arc

Describes methods for initiating the welding arc (scratch and tapping).

Positioning Electrode Holder

Explains correct electrode positioning for groove and fillet welds.

Poor Weld Bead Characteristics

Illustrates common problems with weld beads and their causes.

Good Weld Bead Characteristics

Shows examples of good weld beads and characteristics to aim for.

Conditions That Affect Weld Bead Shape

Details how electrode angle, arc length, and travel speed affect weld bead shape.

Electrode Movement During Welding

Describes stringer and weave bead techniques for different weld joints.

Welding Lap Joints

Illustrates techniques for welding lap joints.

Welding Groove (Butt) Joints

Explains methods for welding groove (butt) joints, including preparation.

Welding T-Joints

Illustrates techniques for welding T-joints.

Weld Test

Describes how to perform a weld test to check for quality and diagnose issues.

Troubleshooting

Guides on troubleshooting common welding issues like porosity and penetration.

GMAW Welding (MIG) Guidelines When Using A Voltage-Sensing Feeder

Typical GMAW (MIG) Process Connections Using A Voltage-Sensing Wire Feeder

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

Holding And Positioning Welding Gun

Details proper techniques for holding and positioning the welding gun.

Conditions That Affect Weld Bead Shape

Explains how gun angle, distance, and speed affect MIG weld bead shape.

Gun Movement During Welding

Describes stringer and weave bead techniques for MIG welding.

Poor Weld Bead Characteristics

Illustrates common poor weld bead characteristics in MIG welding.

Good Weld Bead Characteristics

Shows examples of good weld bead characteristics in MIG welding.

Troubleshooting – Excessive Spatter

Guides on resolving excessive spatter issues in MIG welding.

Troubleshooting – Porosity

Helps diagnose and fix porosity problems in MIG welds.

Troubleshooting – Excessive Penetration

Guides on resolving excessive penetration issues in MIG welding.

Troubleshooting – Lack Of Penetration

Helps diagnose and fix lack of penetration problems in MIG welds.

Troubleshooting – Incomplete Fusion

Guides on resolving incomplete fusion issues in MIG welding.

Troubleshooting – Burn-Through

Helps diagnose and fix burn-through issues in MIG welding.

Troubleshooting – Waviness Of Bead

Guides on resolving wavy bead issues in MIG welding.

Troubleshooting – Distortion

Helps diagnose and fix distortion problems in MIG welding.

Common MIG Shielding Gases

A chart listing common MIG shielding gases and their applications.

Troubleshooting Guide For Semiautomatic Welding Equipment

A guide to troubleshooting wire feed and arc stability issues in MIG welding.

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