Gebruiksaanwijzing /service van het product 250 van de fabrikant Miller Electric
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Bob cat 250 Diesel Processes Description ™ Non-Critical TIG (GT A W) W elding Stick (SMAW ) Welding MIG (GMAW) Welding Flux Cored (FCA W ) W elding Engine Driven Welding Generator OM-217 455H 2007 − 05 − 21 File: Engine Drive V isit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 10 − P ARTS LIST 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Recommended Spare Parts 41 . . . . . . . . . . . . . . . . . . . .
OM-217 455 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-217 455 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-217 455 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery . D Stop engine before disconnecting or connect- ing battery cables or servicing battery .
OM-217 455 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . D Do not touch hot compressor or air system parts.
OM-217 455 Page 5 H. F . RADIA TION can cause interference. D High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation.
OM-217 455 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-217 455 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants.
OM-217 455 Page 8 D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affe c l’ouïe.
OM-217 455 Page 9 D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Le s fumées d’un groupe autonome contient du monoxyde de carbone.
OM-217 455 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur . D Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.
OM-217 455 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) .
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 13 4-2. Dimensions, W eights, and Operating Angles Dimensions Height 35-1/2 in (902 mm) (T o T op Of Exhaust) A B Width 20 in (508 mm) B C ! D d il l i ld Depth 53 in (1346 mm) D ! D o not exceed tilt angles or engine could be damaged or unit could tip.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 14 SECTION 5 − INST ALLA TION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 15 5-2. Installing Exhaust Pipe 804 196-A / Ref. 228 647-A ! Stop engine and let cool. ! Do not blow exhaust toward right side of unit where air inlet is or air cleaner may require frequent service.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 16 5-4. Overview And Engine Prestart Checks 1 Generator Power Receptacles (see Section 7) 2 W eld Output T erminals (see S.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 17 12 11 15 16 17 18 ! Engine shown with doors removed. Doors must be in place when engine is running. Engine Left Side Engine Right Side Engine must be cold and on a level sur- face.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 18 1 W ork Weld Output T erminal 2 Electrode W eld Output T erminal Connect work cable to W ork terminal. Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 19 5-6. Selecting W eld Cable Sizes* W eld Output T erminals ! W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** ! T ur n off power before connecting to weld output terminals.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 20 SECTION 6 − OPERA TING THE WELDING GENERA TOR Ref. 228 647-A 1 4 6-1. Engine Control Switches NOTICE − Disconnect equipment from auxil- iary power receptacles during start − up and shutdown.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 21 13 6-2. W eld Output Controls 1 W eld Process Selector Switch NOTICE − Do not switch while welding.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 22 6-3. T ypical Stick Welding Connections And Control Settings Ref. 804 249-A / Ref 228 647-A ! Stop engine. . This section provides general guidelines and may not suit all applications.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 23 6-4. T ypical MIG Welding Connections And Settings Ref. 804 249-A / Ref 228 647-A / Ref. 802 766-C ! Stop engine. . This section provides general guide- lines and may not suit all ap- plications.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 24 6-5. T ypical MIG Connections And Settings Using Weld Control And Spoolgun Ref. 804 249-A / Ref. 228 647-A / Ref. 802 750-A ! Stop engine. . This section provides general guide- lines and may not suit all applications.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 25 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Generator Power Receptacles 803 750-B / Ref. 21 1 362-A ! If unit does not have GFCI recep- tacles, use GFCI-protected extension cord.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 26 7-2. Simultaneous W eld And Power W eld Current in Amperes T otal Power in Watts 120 V Full kV A Receptacle Amperes 240 V Full kV A Receptacle Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 10,500 (Peak) 88 44 7-3.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 27 SECTION 8 − OPERA TING OPTIONAL BA TTER Y CHARGER 8-1. Battery Charge Controls ! Have only qualified persons charge batteries. ! Do not use battery charger for jump starting.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 28 8-3. Battery Charge Cable Connections ! Stop engine. ! Do not charge a battery which has loose terminals or one showing damage such as a cracked case or cover . ! Have only qualified persons do bat- tery charging work.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 29 8-4. Battery Charging Procedure Stop Engine. Connect Cables (Observe Correct Polarity). T urn Off Battery Charging Switch. Set Charge V oltage Switch T o V oltage Of Battery Being Charged (12, 24, Or 36 V olt).
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 30 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 31 SECTION 9 − MAINTENANCE AND TROUBLESHOOTING 9-1. Routine Maintenance ! Stop engine before maintaining. . S ee Engine Manual and Maintenance Label for important start-up, service, and storage information.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 32 9-2. Maintenance Label And Engine Maintenance Activities 4 3 3 1 8 2 7 6 5 7 ! Stop engine and let cool. Oil And Fuel 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter according to en- gine manual.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 33 804 197-A / Ref 803 1 1 1-A / 227 727.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 34 9-3. Servicing Air Cleaner aircleaner1 9/02 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 35 9-4. Adjusting Engine Speed . If the engine does not start and stop properly , verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following).
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 36 B. Checking Throttle Solenoid Ref. 804 250-A / 802 649 ! Stop engine. If the engine does not stay at idle speed, verify the the throttle solenoid and linkage is installed properly .
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 37 C. Making Engine Speed Adjustments Ref. 804 250-A / 801 963 . Before adjusting engine speed, verify throttle solenoid is installed properly (see Section B on previous page).
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 38 ! Stop engine. . When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Fuse F1 F1 protects the weld excitation winding from overload.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 39 9-6. T roubleshooting T ables A. Welding T rouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 40 T rouble Remedy Low power output at ac receptacles. Increase Fine control R1 setting to max. Check fuse F2, and replace if open (see Section 9-5). High power output at ac receptacles.
. A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 41 T rouble Remedy Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water . Periodically recharge battery (approximately every 3 months).
OM-217 455 Page 42 SECTION 1 1 − ELECTRICAL DIAGRAMS Figure 1 1-1. Circuit Diagram For Welding Generator.
OM-217 455 Page 43 228 719-B.
OM-217 455 Page 44 Figure 1 1-2. Circuit Diagram For Welding Generator With Battery Charging Option.
OM-217 455 Page 45 231 607-B.
OM-217 455 Page 46 SECTION 12 − RUN-IN AND WETST ACKING run_in_D722 9/05 12-1. Run-In And Wetstacking 1 W elding Generator Run-in procedures for this engine should not be required.
OM-217 455 Page 47 SECTION 13 − PERFORMANCE DA T A 13-1. Fuel Consumption Curves 226795-A / 226 796-A Auxiliary Power Fuel Consumption Weld Fuel Consumption DC WELD AMPERES A T 100% DUTY CYCLE US Gal./Hr . IDLE 0 50 100 150 200 250 300 350 400 0.00 0.
OM-217 455 Page 48 226 791-A The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 13-2. Generator Power Curve AC Amperes At 240 V olts 0 AC V olts 0 20 40 60 80 100 120 50 100 150 200 250 300 0 40 80 120 160 200 240 AC Amperes At 120 V olts 0 25 50 75 100 125 150 Continuous Welding 13-3.
OM-217 455 Page 49 226 792-A / 226 793-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. A. CC/DC Stick Mode 13-4. Stick Mode V olt-Ampere Curves B.
OM-217 455 Page 50 226 794-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown.
OM-217 455 Page 51 SECTION 14 − GENERA TOR POWER GUIDELINES . The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 14-1. Selecting Equipment gen_pwr 2007 − 04 − Ref.
OM-217 455 Page 52 14-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.
OM-217 455 Page 53 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Sta rting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP.
OM-217 455 Page 54 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-.
OM-217 455 Page 55 14-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP .
OM-217 455 Page 56 14-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-217 455 Page 57 14-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-217 455 Page 58 SECTION 15 − STICK WELDING (SMA W) GUIDELINES 15-1. Stick W elding Procedure stick 2007 − 04 − ST-151 593 ! W eld current starts when electrode touches work- piece. ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle.
OM-217 455 Page 59 15-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1.
OM-217 455 Page 60 15-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide View of Electrode Angle 10 ° -30 ° 15-6.
OM-217 455 Page 61 15-8. Conditions That Affect Weld Bead Shape . W el d bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRA V EL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 15-9.
OM-217 455 Page 62 15-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W el d Good for materials up to 3/16 in (5 mm) thick.
OM-217 455 Page 63 15-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 15-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal.
OM-217 455 Page 64 15-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage.
OM-217 455 Page 65 15-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode.
Notes W or k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual ..
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters.
Een belangrijk punt na aankoop van elk apparaat Miller Electric 250 (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Miller Electric 250 heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Miller Electric 250 vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Miller Electric 250 leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Miller Electric 250 krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Miller Electric 250 bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Miller Electric 250 kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Miller Electric 250 . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
