Miller Bobcat 3 Phase Owner's Manual
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Miller Bobcat 3 Phase Owner's Manual

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Bobcat 3 Phase
™
OM-4436
220 542J
2007−03
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welding Generator
File: Engine Drive

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  • Page 1 OM-4436 220 542J 2007−03 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Non-Critical TIG (GTAW) Welding Description Engine Driven Welding Generator Bobcat 3 Phase ™ File: Engine Drive Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − TROUBLESHOOTING ............9-1.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. Welding on closed containers, such as tanks, drums, or D Allow cooling period before working on equipment. pipes, can cause them to blow up. Sparks can fly off from the welding arc.

  • Page 7: Compressed Air Hazards

    D Use only genuine Miller/Hobart replacement parts. 1-5. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. ARC WELDING can cause interference. D Use only genuine MILLER/Hobart replacement D Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as D Perform engine and air compressor (if applicable) robots.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles signi- présente des risques de danger ! Ceux-ci sont identifiés fie Mise en garde ! Soyez vigi-...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chaudes. Le soudage effectué sur des conteneurs fermés tels que des D Prévoir une période de refroidissement avant de travailler à réservoirs, tambours ou des conduites peut provoquer leur l’équipement.

  • Page 11: Dangers Liés À L'air Comprimé

    éléments ou avant d’ouvrir la fectuer la maintenance. purge ou le bouchon de remplissage d’huile. D Utiliser uniquement des pièces de rechange Miller/Hobart. 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance L’EMPLOI EXCESSIF peut...

  • Page 12: Proposition Californienne 65 Avertissements

    LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de provoquer des interférences. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur D L’énergie électromagnétique risque de provoquer des in- (si applicable) suivant ce manuel et le manuel du moteur/ terférences pour l’équipement électronique sensible tel compresseur (si applicable).

  • Page 13: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch while Engine Choke Work Connection Clearance...

  • Page 14: Dimensions, Weights, And Operating Angles

    A complete Parts List is available at www.MillerWelds.com 4-2. Dimensions, Weights, and Operating Angles Dimensions 33-1/2 in (851 mm) Height (To Top Of Exhaust) Width 20 in (508 mm) Y Do not exceed tilt angles or engine could be damaged or unit could tip. ld ti Depth 45-3/8 in (1153 mm)

  • Page 15: Generator Power Curves

    A complete Parts List is available at www.MillerWelds.com 4-4. Generator Power Curves The generator power curves show the generator power in amperes available at the receptacles. A. 10 kVA/kW Single-Phase Power B. 11 kVA/kW Three-Phase Power 200 294 / 210 724 OM-4436 Page 11...

  • Page 16: Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-5. Volt-Ampere Curves The volt-ampere curve shows the A. For CC/AC Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 17: Fuel Consumption

    A complete Parts List is available at www.MillerWelds.com 4-6. Fuel Consumption On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration. Welding at 150 amps at 40% duty cycle uses approximately 3/4 gal- lon per hour, or about 16 hours of operation.

  • Page 18: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Y Always securely fasten weld- Y Do not lift unit from end.

  • Page 19: Engine Prestart Checks

    A complete Parts List is available at www.MillerWelds.com 5-2. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. This unit has a low oil pressure shutdown switch.

  • Page 20: Installing Exhaust Pipe

    A complete Parts List is available at www.MillerWelds.com 5-3. Installing Exhaust Pipe Y Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel.

  • Page 21: Connecting To Weld Output Terminals

    A complete Parts List is available at www.MillerWelds.com 5-5. Connecting to Weld Output Terminals Y Stop engine. Work Weld Output Terminal Electrode Weld Output Terminal Connect work cable to Work terminal. Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding.

  • Page 22: Selecting Weld Cable Sizes

    A complete Parts List is available at www.MillerWelds.com 5-6. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m)

  • Page 23: Section 6 − Operating The Welding Generator

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Front Panel Controls Ref. 228 197-A Engine Control Switch Oil Change Interval: With engine off, place En- Coarse Range Switch gine Control switch in the Run position to see Use switch to start engine, select speed, and Y Do not switch under load.

  • Page 24: Cold Weather Engine Operation

    A complete Parts List is available at www.MillerWelds.com 6-2. Cold Weather Engine Operation Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the rela- Infrequently tive humidity is high.

  • Page 25: Typical Stick Welding Connections And Control Settings

    A complete Parts List is available at www.MillerWelds.com 6-3. Typical Stick Welding Connections And Control Settings Y Stop engine. This section provides general guidelines and may not suit all applications. For best arc starts and best The control panel shows the typi- results using weld and generator cal settings for welding with a power together, use a low...

  • Page 26: Typical Mig Welding Connections And Settings

    A complete Parts List is available at www.MillerWelds.com 6-4. Typical MIG Welding Connections And Settings A. Solid Wire Applications Y Stop engine. This section provides general guide- lines and may not suit all ap- plications. Typical Control Settings For .035 (ER70S-3) Solid Wire −...
  • Page 27 A complete Parts List is available at www.MillerWelds.com B. Self-Shielded Flux Core Wire Applications Y Stop engine. This section provides general guidelines and may not suit all applications. Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire The control panel shows the typi- cal settings for welding with .045 (71T-11) self-shielded flux core Note Coarse Range,...

  • Page 28: Typical Mig Connections And Settings Using Weld Control And Spoolgun

    A complete Parts List is available at www.MillerWelds.com 6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun Typical Settings For 4043 (.035) Aluminum On 1/8 in Material: Note Coarse Range and Weld Process switch settings. Tools Needed: 3/4 in Connect to unused Work contactor terminal.

  • Page 29: Section 7 − Operating Auxiliary Equipment

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Standard Receptacles Generator power decreases as weld current increases. Set Fine Control R1 at 10 for full generator power. 120/240 V 50 A Single-Phase AC Receptacle RC1 120 V 20 A AC GFCI Recep- tacles GFCI2 and GFCI3 480 V 30 A Three-Phase AC...

  • Page 30: Wiring Optional 240 Volt Plug

    A complete Parts List is available at www.MillerWelds.com 7-2. Wiring Optional 240 Volt Plug The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each duplex receptacle shares a load...

  • Page 31: Section 8 − Maintenance

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE 8-1. Maintenance Label OM-4436 Page 27...

  • Page 32: Routine Maintenance

    A complete Parts List is available at www.MillerWelds.com 8-2. Routine Maintenance Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Y Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids.

  • Page 33: Servicing Air Cleaner

    A complete Parts List is available at www.MillerWelds.com 8-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Precleaner Wash precleaner with soap and wa- ter solution. Allow precleaner to air dry completely.

  • Page 34: Changing Engine Oil, Oil Filter, And Fuel Filter

    A complete Parts List is available at www.MillerWelds.com 8-4. Changing Engine Oil, Oil Filter, and Fuel Filter Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine owner’s manual.

  • Page 35: Adjusting Engine Speed

    A complete Parts List is available at www.MillerWelds.com 8-5. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 − 2300 rpm Start engine and run until warm. (36.6 − 38.3 Hz) Turn Fine Control to 10.

  • Page 36: Overload Protection

    A complete Parts List is available at www.MillerWelds.com 8-6. Overload Protection Y Stop engine. Disconnect negative (−) battery cable. Fuse F1 (See Section 10-1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low. Fuse F6 located in Fuse F2 (See Section 10-1) engine harness on...

  • Page 37: Section 9 − Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − TROUBLESHOOTING 9-1. Welding Troubleshooting Trouble Remedy Low or no weld output; generator pow- Check control settings. er output okay at ac receptacles. Check weld connections. Check fuse F1, and replace if open (see Section 8-6). Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi- ers SR2 and SR3.

  • Page 38: Engine Troubleshooting

    A complete Parts List is available at www.MillerWelds.com Trouble Remedy No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit. Check fuses F1 and F2, and replace if open (see Section 8-6). Check plug PLG6 connection. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi- ers SR2 and SR3.

  • Page 39: Section 10 − Parts List

    A complete Parts List is available at www.MillerWelds.com Trouble Remedy Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. Engine idles but does not come up to Have Factory Authorized Service Agent check hour meter/idle module, and current transformer CT1.

  • Page 40: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS 231 627-A Figure 11-1. Circuit Diagram For Welding Generator OM-4436 Page 36...

  • Page 41: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...
  • Page 42 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 43 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 44 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 45 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP AC MOTOR Motor Voltage VOLTS AMPS To find starting amperage: CODE Step 1: Find code and use table to PHASE find kVA/HP.
  • Page 46 12-10. Typical Connections To Supply Standby Power Y Have only qualified persons perform these connections according to all applicable codes and safety practices. Y Properly install and ground this equipment according to its Owner’s Manual and na- tional, state, and local codes. Fused Welding Utility...
  • Page 47 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 48: Section 13 − Stick Welding (Smaw) Guidelines

    SECTION 13 − STICK WELDING (SMAW) GUIDELINES 13-1. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.
  • Page 49 13-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...
  • Page 50 13-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 13-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...
  • Page 51 13-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...
  • Page 52 13-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...
  • Page 53 13-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 13-14. Troubleshooting − Porosity Porosity −...
  • Page 54 13-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
  • Page 55 13-19. Troubleshooting − 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. Increase and/or maintain steady travel speed. 13-20. Troubleshooting − Waviness Of Bead Waviness Of Bead −...

  • Page 56: Section 14 − Mig Welding (Gmaw) Guidelines

    SECTION 14 − MIG WELDING (GMAW) GUIDELINES 14-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a Constant vehicle. Place work clamp as Current (CC) close to the weld as possible.
  • Page 57 14-3. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...
  • Page 58 14-4. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...
  • Page 59 14-7. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
  • Page 60 14-10. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
  • Page 61 14-13. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.
  • Page 62 14-15. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 63 Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...

  • Page 64: Options And Accessories

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © PRINTED IN USA 2007 Miller Electric Mfg. Co. 2007−01...

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