Miller Bobcat 265 Air Pak Owner's Manual
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Miller Bobcat 265 Air Pak Owner's Manual

Miller Bobcat 265 Air Pak Owner's Manual

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OM-296490C
2024-11
Processes
Multiprocess Welding
Description
Engine Driven Welder/Generator
Bobcat
265 Air Pak
™
™
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-296490C 2024-11 Processes Multiprocess Welding Description Engine Driven Welder/Generator Bobcat 265 Air Pak ™ ™ OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS 6-11 Typical MIG Welding Connections and Settings............... . . 43 6-12 Typical Spool Gun Welding Connections And Control Settings .

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

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- � Ne pas souder des métaux munis d’un revêtement, tels que l’acier champ les pièces endommagées. Entretenir l’appareil conformé- galvanisé, plaqué en plomb ou au cadmium à moins que le revête- ment à...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas effectuer le soudage sur des conteneurs fermés tels que � Les porteurs d’implants médicaux doivent consulter leur médecin des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été et le fabricant du dispositif avant de s’approcher de la zone où se préparés correctement conformément à...

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas faire le plein de carburant à ras bord; prévoir de l’espace � Prévoir une période de refroidissement avant de travailler à pour son expansion. l’équipement. � Faire attention de ne pas renverser de carburant. Nettoyer tout � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- carburant renversé...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    MÉTAL CHAUD provenant du Une PRESSION D’AIR RÉSIDUELLE découpage ou du gougeage à l’arc ETDES FLEXIBLES QUI FOUETTENT risque de provoquer un incendie ou risquent de provoquer des une explosion. blessures. � Détendre la pression pneumatique des outils et circuits avant �...
  • Page 16 � Suivre les consignes du Manuel des applications pour l’équation � Ne charger que des batteries plomb-acide. Ne pas utiliser le char- de levage NIOSH révisée (Publication № 94–110) lors du levage geur de batterie pour alimenter un autre circuit électrique basse manuelle de pièces ou équipements lourds.

  • Page 17: Proposition Californienne 65 Avertissements

    � Contactez votre bureau de recyclage local ou votre distributeur lo- � Si le FCC signale des interférences, arrêter immédiatement cal pour obtenir des informations sur la manière de mettre au re- l’appareil. but les pièces et l’équipement d’une manière respectueuse de �...

  • Page 18: Informations Relatives Aux Cem

    2-8. Informations relatives aux CEM 3. Ne pas courber et ne pas entourer les câbles autour de votre Le courant électrique qui traverse tout conducteur génère des corps. champs électromagnétiques (CEM) à certains endroits. Le courant is- su d’un soudage à l’arc (et de procédés connexes, y compris le sou- 4.

  • Page 19: Section 3 - Definitions

    Safe � Complete Parts List is available at www.MillerWelds.com SECTION 3 – DEFINITIONS Falling unit can cause injury and damage. Do not move unit where two wheels are at a different height and un could tip avoid tipping. Be careful when moving unit over uneven surfaces. Safe 3-1.
  • Page 20 � Complete Parts List is available at www.MillerWelds.com Engine Off Fuel Engine Choke Hertz Engine Idle (Slow) Percent Battery (Engine) Run (Fast) Air Filter Engine Air Compressor Engine Start Spool Gun (Engine RPM) Air Pressure Engine Stop OM-296490 Page 16...

  • Page 21: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 22: Environmental Specifications

    � Complete Parts List is available at www.MillerWelds.com 4-8. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.

  • Page 23: Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.MillerWelds.com 4-9. Dimensions, Weights, And Operating Angles Dimensions External Dimensions Height (With Exhaust) 31 in. (787 mm) Do not exceed tilt angles or engine could Width 20.46 in. (520 mm) be damaged or unit could tip. Depth 51.88 in.

  • Page 24: Duty Cycle And Overheating

    � Complete Parts List is available at www.MillerWelds.com 4-10. Duty Cycle And Overheating Duty cycle is the percentage of 10 minutes 100% Duty Cycle at 265 Amperes DC that unit can weld at rated load without overheating. � This unit is rated for welding at 265 am- peres continuously.

  • Page 25: Fuel Consumption Curves

    � Complete Parts List is available at www.MillerWelds.com 4-11. Fuel Consumption Curves WeldIng Weld Power Run No-Load Idle AMPERES Auxiliary Power Aux Power Run No-Load Idle KILOWATTS OM-296490 Page 21...
  • Page 26 � Complete Parts List is available at www.MillerWelds.com Air Compressor 160 psi (1100 kPa) AIR PRESSURE OM-296490 Page 22...

  • Page 27: Stick Mode Volt-Ampere Curves

    � Complete Parts List is available at www.MillerWelds.com 4-12. Stick Mode Volt-Ampere Curves The volt-ampere curves show the minimum XX10 Electrode and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. 25 Amps 260 Amps 140 Amps...

  • Page 28: Mig Mode Volt-Ampere Curves

    � Complete Parts List is available at www.MillerWelds.com 4-13. MIG Mode Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. 30 Volts 22 Volts 14 Volts Amps...

  • Page 29: Generator Power Curve

    � Complete Parts List is available at www.MillerWelds.com 4-15. Generator Power Curve The AC generator power curve shows the 120 Volt generator power available in amperes at the receptacles. Tools and motors are designed to operate within 10% of 120/240 VAC. Amps 240 Volt Amps...

  • Page 30: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com 1-1. Installing Welder/Generator SECTION 5 – INSTALLATION 1-1. Installing Welder/Generator 5-1. Installing Welder/Generator Complete Parts List available at www.MillerWelds.com Do not move or operate unit where Movement it could tip. Do not lift unit from end. Do not weld on base.

  • Page 31: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle shock and static electricity hazards.

  • Page 32: Installing Exhaust Pipe

    � Complete Parts List is available at www.MillerWelds.com 5-4. Installing Exhaust Pipe Stop engine and let cool. Engine backfire can cause severe burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust RUN/IDLE outlet. START Do not point exhaust pipe toward LP fuel tank (if equipped).

  • Page 33: Engine Prestart Checks

    � Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with synthetic blend 10W-30 engine oil. � Follow run-in procedure in engine manual.

  • Page 34: Compressor Prestart Checks

    NOTICE – Do not mix oil types. Do not over- Bottom of oil sight glass is minimum oil replace if dirty (see Section 12-3). fill. Use Miller Electric compressor oil. See level. Top of oil sight glass is full. maintenance label in Section 12-2.

  • Page 35: Connecting Or Replacing The Battery

    � Complete Parts List is available at www.MillerWelds.com 5-7. Connecting Or Replacing the Battery Connect negative (-) battery cable last. Battery is most easily accessed by opening right rear side panel. � Do not allow the battery cables to touch opposing terminals.

  • Page 36: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-8. Weld Output Terminals Stop engine. Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Positive Weld Output Terminal RUN/IDLE 2 Negative Weld Output Terminal START 3 Spool gun receptacle Connect electrode or torch cable to positive...

  • Page 37: Spool Gun Receptacle Information

    � Complete Parts List is available at www.MillerWelds.com 5-10. Spool Gun Receptacle Information Socket* Socket Information Motor Positive (+) 0 to 24 volts DC Motor Negative (-) 0 volts Spool Gun Trigger 15 volts DC Spool Gun Trigger 0 volts 10V Reference WFS Potentiometer 0 to 10 volts DC Common...

  • Page 38: Connecting To Air Compressor

    � Complete Parts List is available at www.MillerWelds.com 5-12. Connecting To Air Compressor Stop engine and release air pres- sure before servicing compressor. 1 Air Compressor Outlet JIC 8 Male 2 Supplied Fitting JIC 8 Female to 1/2 in. Push On Hose Barb 3 Air Hose Routing Options Supplied fitting can be used to connect a 1/2 in hose to air compressor outlet.

  • Page 39: Section 6 - Operation

    SECTION 6 – OPERATION 6-1. Front Panel Controls CHARGE RUN/IDLE Auto-Set ™ START 4 Auto-Set 1 Engine Control Switch � During cold weather some gasoline en- gines encounter difficulties that are Push to set parameters based on pre-de- Use switch to start engine, select speed, easily remedied.

  • Page 40: Main Screen

    6-2. Main Screen Displays current amp setting (CC). 8 Pressure Gauge 1 Fuel Level Displays welding current (CV). Displays current compressor pressure. Displays current fuel level. 5 Process Selection Button 9 Menu Button 2 Weld Process Opens process selection screen. Opens Main Menu Screen.

  • Page 41: Menu Screen

    6-3. Menu Screen 1 System Settings 3 System Info 5 Troubleshooting Select to change unit operation parameters. Select to check and update software, check Displays live unit data for troubleshooting See Section 6-4. and download summary file, and restore unit purposes.

  • Page 42: System Settings Screen

    6-4. System Settings Screen To change System Settings: � Rotate Adjust Control/Select button to select a setting. � Press Adjust Control/Select button on desired setting. � Rotate Adjust Control/Select button to update the setting. � Press Adjust Control/Select button to save the setting, or press the Back but- ton to discard setting change.

  • Page 43: Process Screen

    6-6. Process Screen 1 Process Button 2 Menu Button To change weld process, rotate Adjust Con- trol/Select button to desired process and press button to select. Press to open process selection screen. Press to open Menu. Process Typical Process Application Polarity SMAW XX18 (STICK) Constant current process.

  • Page 44: Weld Settings

    6-7. Weld Settings To access the weld settings, press the Set- tings button. To change a particular parameter (parame- ters change based on current process): � Rotate the Adjust Control/Select knob to the specific parameter. � Press the Adjust Control/Select knob to select.

  • Page 45: Auto-Set Functionality

    6-8. Auto-Set Functionality ™ 1 Auto-Set Button Press to turn Auto-Set On or Off. 2 Auto-Set Option 1 3 Auto-Set Option 2 4 Auto-Set Option 3 Rotating knob clockwise moves cursor left, rotating counterclockwise moves cursor right. Press knob or NEXT button to select option CHARGE and move to next selection.

  • Page 46: Stick Start Procedure-Scratch Start Technique

    For optimal starting performance, a good clean contact must be made between the electrode and workpiece. � Miller recommends Hobart filler metals. 6-10. Typical Stick Welding Connections And Control Settings Stop engine. � This section provides general guide- lines and may not suit all applications.

  • Page 47: Typical Mig Welding Connections And Settings

    6-11. Typical MIG Welding Connections and Settings A. Solid Wire Applications Stop engine. � This section provides general guide- lines and may not suit all applications. 1 Work Clamp 2 Wire Feeder 3 MIG Gun 4 Gun Trigger Plug 5 Voltage Sensing Clamp 6 Gas Cylinder: 75/25 Argon-Based Gas for Short Circuit Transfer;...
  • Page 48 UI onto wire feeder. � Do a test weld. To increase arc length, increase voltage. To decrease arc length reduce voltage or increase wire feed speed. � Miller recommends Hobart filler metals. 3/4 in. philips head wrench crescent wrench nutdriver...

  • Page 49: Typical Spool Gun Welding Connections And Control Settings

    3/4 in. � � � ps head wrench crescent wrench Be sure to use the correct size weld Miller recommends Hobart filler This section provides general guide- cables (see Section 5-11). metals. lines and may not suit all applications. Connect Weld power cable from spool gun...

  • Page 50: Cold Weather Engine Operation

    6-13. Cold Weather Engine Operation RUN/IDLE RUN/IDLE START START Synthetic Oil 1 Engine Control Switch — For cold starts � Do not extend the recommended oil and engine warm up. change interval when using synthetic For temperatures below zero (0° F), syn- oil.

  • Page 51: Updating Software

    6-14. Updating Software Preparing For Software Update Step 1. Verify current software version installed. Step 2. Press Settings button and use Adjust Control/Select button to select System Info. The current software revision is displayed. Step 3. Verify that USB thumb drive is good by inserting it into USB receptacle on bottom of remote panel. Press ”Download Service File" from menu.

  • Page 52: Section 7 - Compressor Operation

    SECTION 7 – COMPRESSOR OPERATION 7-1. Air Compressor Operation � Weld output and generator power may be reduced when the air compressor is 1 Air Compressor Operation Button While in the Weld screen, press the Air Com- pressor Operation button to toggle the com- pressor output.
  • Page 53 1/2 in. ID Hose 20 Gallon (Recommended) 10 Gallon (Minimum) Air Tank Air Pressure Quick Regulator Connect Ball-Valve Drain For air usage greather than the compressor The more the continuous CFM of the tool ex- Connect a 20– gallon (recommended; 10– output (30 CFM), the air tank supplements ceeds the rating of the compressor, the larg- gallon minimum) air tank to the air compres-...

  • Page 54: Air Compressor Controls

    7-3. Air Compressor Controls After the air compressor shuts off, 4 Temperature Sensor Compressor Idle Down And Standby the blow down cycle begins and Mode Compressor shuts down due to over-tem- takes several minutes. When gauge perature and “Air Comp Over Temp” dis- reads zero, open cap slowly to re- 6 Compressor Outlet plays.

  • Page 55: Section 8 - Battery Charging

    SECTION 8 – BATTERY CHARGING 8-1. Battery Charging Guidelines Keep battery charging cables away Disconnect cables from weld termi- Stop welder/generator engine. from vehicle hood, door, and mov- nals before charging a battery. Weld ing parts. terminals are electrically live during Before charging battery, read the Safety Precautions at the beginning battery charging.

  • Page 56: Connecting Installed Battery To Battery Charge Receptacle

    8-3. Connecting Installed Battery To Battery Charge Receptacle Negative Post Grounded Stop welder/generator engine. Place � Battery will not charge if it is com- Air Compressor switch in the Off pletely dead. This happens at 1 volt. If battery Negative (−) post is grounded to position.

  • Page 57: Setting Battery Charge Controls

    8-4. Setting Battery Charge Controls To start charging a battery: � Select either 12 V or 24 V with the con- trol/select button depending on the type of battery being charged. � Connect the battery terminals as de- scribed in Section 8-2 and 8-3. �...

  • Page 58: Section 9 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – OPERATING AUXILIARY EQUIPMENT 9-1. Generator Power Receptacles Maximum output from duplex receptacles is 6 Supplementary Protector CB3 Use GFCI protection when operating 2.4 kVA/kW. auxiliary equipment. If unit does not have GFCI receptacles, use GFCI- CB3 protects duplex receptacles from over- 120/240 V receptacle supplies 240 V 60 Hz...

  • Page 59: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 9-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 60: Simultaneous Weld And Power

    � Complete Parts List is available at www.MillerWelds.com 9-3. Simultaneous Weld And Power Weld Current in Amperes At 30 Total Power Available in Watts 120 V Receptacle Amperes 240 V Receptacle Amperes Volts DC 1600 4600 Complete Parts List available at www.MillerWelds.com 6300 7300 9500...

  • Page 61: Wiring Instructions For 240 Volt, Single-Phase Plug (Nema 6-50P)

    � Complete Parts List is available at www.MillerWelds.com 9-5. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P) The plug can be wired for a 240 V, 2-wire load. 1 Plug Wired for 240 V, 2-Wire Load 2 Load 1 (Brass)Terminal 3 Load 2 (Brass) Terminal 4 Ground (Green) Terminal Current Available in Amperes...

  • Page 62: Section 10 - Can-Bus Connection

    SECTION 10 – CAN-BUS CONNECTION 10-1. CAN-Bus Connection 1 CAN-Bus Connector A CAN-bus connection is provided to allow read-only data communication. The data is available through the CAN-bus connector lo- cated inside right-hand access door, on the main harness. Data is transmitted when the unit is On.

  • Page 63: Trailblazer J1939 Messages

    10-2. Trailblazer J1939 Messages Message Notes Acro- ID (Hex) Start Length (Deci- Posi- (Deci- Rate mal) tion mal) (ms) Engine Speed 0 to 8031.875rpm 0.125rpm/bit 0 EEC1 0CF004D1 61444 2 bytes offset Battery Potential 0 to 3212.75V, 0.05V/bit, 0 offset 18FEF7D1 65271 2 bytes...
  • Page 64 Table 10–2. Error State Error Value Detection NO ERROR WELD BOOST CONNECTOR FAULT Connector RC2 not plugged in. WELD BOOST VBUS HIGH FAULT Weld module bus voltage exceeded threshold during operation. WELD BOOST VBUS LOW FAULT Weld module bus voltage below threshold while engine running. WELD BOOST FAULT Low weld module bus voltage after soft start.
  • Page 65 Table 10–3. DM1 Definitions J1939-73 SPN Name Detection DTC Set Parameter Time to action or Recov- SAE J1939 number of error Action ery From Table C1 detection Error ETB: Stuck 5419 Engine Throt- Throttle performance - Movement of the 1.6 seconds tle Actuator stuck throttle blade is...
  • Page 66 J1939-73 SPN Name Detection DTC Set Parameter Time to action or Recov- SAE J1939 number of error Action ery From Table C1 detection Error start- ing. Engine temp: Engine Engine temp signal Voltage in ETS cir- 12.5 seconds Typical- No longer Low/Grounded Temperature low/grounded...
  • Page 67 J1939-73 SPN Name Detection DTC Set Parameter Time to action or Recov- SAE J1939 number of error Action ery From Table C1 detection Error calibra- tion Oxygen Sensor: 3056 Engine Oxy- O2 (common or cyl 1) Voltage in O2 circuit 225.0 seconds Engine No longer...
  • Page 68 J1939-73 SPN Name Detection DTC Set Parameter Time to action or Recov- SAE J1939 number of error Action ery From Table C1 detection Error Closed Loop Fuel 4237 proprietary Lean at high load/ If O2 signal falls be- 20.0 seconds Fuel O2 sen- Adaption: Lean...

  • Page 69: Section 11 - Generator/Engine Maintenance

    SECTION 11 – GENERATOR/ENGINE MAINTENANCE 11-1. Maintenance Screen The Maintenance screen displays hours re- maining for service items and allows the user to reset service hours and change the inter- val (only shorter than recommended.) Press the Home Button to go to the Home screen.

  • Page 70: Routine Generator/Engine Maintenance

    11-2. Routine Generator/Engine Maintenance � Use information displayed on the LCD display to assist in scheduling maintenance (see Section 11-1). � Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by a Factory Authorized Service Agent.

  • Page 71: Maintenance Label

    11-3. Maintenance Label OM-296490 Page 67...

  • Page 72: Servicing Air Cleaner

    11-4. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty. 1 Precleaner Wash precleaner with soap and water solu- tion.

  • Page 73: Changing Engine Oil, Oil Filter, And Fuel Filter

    11-5. Changing Engine Oil, Oil Filter, And Fuel Filter tools Stop engine and let cool. 1 Oil Drain Valve 2 Oil Filter Change engine oil and filter according to en- gine owner’s manual. NOTICE – Close valve and valve cap before rubbergloves weldgloves earmuffs...

  • Page 74: Overload Protection

    11-6. Overload Protection AUTO-SPEED START 7, 8 Protects voltage regulator from overload. If Protects all receptacles from overload. If Stop engine. open battery will not charge. open the receptacles will not work. � When a circuit breaker, supplementary 4 Fuse F4 (Inside Front Panel) 8 Circuit Breaker CB3 (Under Cover) protector or fuse opens, it usually indi- cates a more serious problem exists.

  • Page 75: Servicing Optional Spark Arrestor

    11-7. Servicing Optional Spark Arrestor Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark ar- restor if screen wires are broken or missing. RUN/IDLE START tools/ flathead philips head wrench crescent wrench 1/4 in. ps head wrench crescent wrench...

  • Page 76: Section 12 - Air Compressor Maintenance

    SECTION 12 – AIR COMPRESSOR MAINTENANCE 12-1. Maintenance � Replace compressor oil and filter after the first 50 hours of operation. Stop engine before maintaining. � See compressor Maintenance Label for important start-up and service information. Service compressor more often if used in severe conditions.

  • Page 77: Compressor Maintenance Label

    12-2. Compressor Maintenance Label AIR COMPRESSOR 250 h MILLER: 232208* 500 h / 1 yr 1000 h / 1 yr MILLER: 232207* Air/Oil Separator MILLER: 275648* 2000 h / 2 yr MILLER: 274630 Dayco: 6060470 MILLER: 276620* * FILTER KIT 275644 contains 2 qt (1.9 L)

  • Page 78: Servicing Compressor Air Cleaner And Air/Oil Separator

    12-3. Servicing Compressor Air Cleaner And Air/Oil Separator Stop engine. Always put Engine Control Switch in the Off position before working unit prevent automatic starting. Do not open oil fill cap until unit has been off for 10 minutes and the air compressor gauge reads zero.

  • Page 79: Section 13 - Troubleshooting

    SECTION 13 – TROUBLESHOOTING 13-1. Front Panel Display Code Information LCD Message Help Code Problem Possible Cause Potential Solution Engine Oil Pressure Error - ERR PF00 Despite RPM, oil pressure Indicates malfunction of the Contact a Factory Authorized Have Unit Serviced switch is ON.
  • Page 80 LCD Message Help Code Problem Possible Cause Potential Solution Boost Over Current Error - ERR EG00 Inverter Control board de- Indicates malfunction in the Contact a Factory Authorized Have Power Module tected boost current over primary power circuit of the Service Agent.
  • Page 81 LCD Message Help Code Problem Possible Cause Potential Solution Batt Read Open Error - ERR BU00 Battery is disconnected or re- Disconnected battery. Check battery connection. Check Battery Connection verse connected. Batt Check Open Error - ERR BU01 Battery is disconnected. Disconnected battery.

  • Page 82: Welding Troubleshooting

    13-2. Welding Troubleshooting Trouble Remedy No weld output. Check weld control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Increase front panel voltage/amperage control settings (see Section 6-7). Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 PC2. Low weld output.

  • Page 83: Engine Troubleshooting

    13-4. Engine Troubleshooting Trouble Remedy Engine will not crank. Check supplementary protector(s) and Fuse F2 (see Section 11-6). Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG1 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine does not start.

  • Page 84: Compressor Troubleshooting

    13-5. Compressor Troubleshooting Trouble Remedy Air compressor does not operate; no Place Air Compressor switch in an On position. If compressor is turned off, wait for air pressure to air pressure on gauge. bleed off before turning compressor on again. Circuit breaker CB6 is open.

  • Page 85: Battery Charge/Jump Troubleshooting

    Trouble Remedy Oil in air from compressor Check compressor oil level (see Section 5-6). If oil level is too high, system becomes saturated with oil. Open line (nothing connected to compressor outlet) will result in oil in air. Do not operate with open air line.

  • Page 86: Section 14 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 14 – PARTS LIST 14-1. Recommended Spare Parts Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity 292189 Brushholder Assy, Generator 280236 Receptacle, Gfci 15/20a 281760 Fuse, Mini Blade Atm 20. Amp 32 Volt 292831 Fuse, Auto 60a 32vdc Auto Link CB3, CB4...
  • Page 87 Notes...

  • Page 88: Section 15 - Diagrams

    SECTION 15 – DIAGRAMS Figure 15-1. Circuit Diagram Page 1 of 2 OM-296490 Page 84...
  • Page 89 296492-B-1 OM-296490 Page 85...
  • Page 90 Figure 15-2. Circuit Diagram Page 2 of 2 OM-296490 Page 86...
  • Page 91 296492-B-2 OM-296490 Page 87...
  • Page 92 290135-A Figure 15-3. Air Compressor Diagram OM-296490 Page 88...

  • Page 93: Section 16 - Generator Power Guidelines

    SECTION 16 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine/hydraulic-driven welder/generators. Your unit may differ from those shown. 16-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 94 16-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (shop,...
  • Page 95 16-5. 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 96 16-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment 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...

  • Page 97: Power Required To Start Motor

    16-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 98 16-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...

  • Page 99: Selecting Extension Cord (Use Shortest Cord Possible)

    16-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)
  • Page 100 Notes...
  • Page 101 Notes...
  • Page 102 Notes...
  • Page 103 Effective January 1, 2024 (Equipment with a serial number preface of NE or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...

  • Page 104: Owner's Record

    Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2024-11...

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