Miller Bobcat 225G - Manuals

Miller Bobcat 225G – Manual in PDF format online.

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Manual

Manual Miller Bobcat 225G

Summary

Page 2 - TABLE OF CONTENTS

OM-175 104B – 1/97 TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 3 - SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING; Symbol Usage; Arc Welding Hazards; WARNING; ELECTRIC SHOCK can kill.

OM-175 104 Page 1 SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_rom1 4/95 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with thisprocedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOC...

Page 4 - Engine Hazards; ENGINE EXHAUST GASES can kill.; MOVING PARTS can cause injury.

OM-175 104 Page 2 CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode.Since gas cylinders are normally part of the weldingprocess, be sure to treat them carefully. 1. Protect compressed gas cylinders from excessive heat,mechani...

Page 5 - Additional Installation, Operation, And Maintenance Hazards; Principal Safety Standards; EMF Information

OM-175 104 Page 3 1-4. Additional Installation, Operation, And Maintenance Hazards MOVING PARTS can cause injury. 1. Before working of generator, remove spark plugsor injectors to keep engine from kicking back orstarting. 2. Block flywheel so that it will not turn while workingon generator component...

Page 6 - SECTION 2 – DEFINITIONS; Symbol Definitions

OM-175 104 Page 4 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow(Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check Valve Clearance Do not switch while welding Work Conne...

Page 7 - SECTION 3 – INSTALLATION; Installing Welding Generator

OM-175 104 Page 5 SECTION 3 – INSTALLATION 3-1. Installing Welding Generator install1* 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grou...

Page 8 - Fuel Consumption; Engine Prestart Checks

OM-175 104 Page 6 3-3. Fuel Consumption Ref. SB-179 939 0.0 0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 0 25 50 75 100 125 150 175 200 225 250 275 7.57 6.62 5.67 4.73 3.78 2.84 1.89 0.95 1.67 1.46 1.25 1.04 0.84 0.63 0.42 0.21 LITERS/HR. IMP. GAS/HR. U.S. GAL/HR. WELD AMPERES AT 100% DUTY CYCLE POWER KVA AT 100...

Page 10 - SECTION 4 – OPERATING WELDING GENERATOR; Front Panel Controls

OM-175 104 Page 8 SECTION 4 – OPERATING WELDING GENERATOR 4-1. Front Panel Controls Ref. ST-178 079-A 1 Engine Control Switch Use switch to start engine, select speed,and stop engine. In Run/Idle position, en-gine runs at idle speed at no load, and weld/power speed under load. In Run position,engine...

Page 11 - Duty Cycle

OM-175 104 Page 9 4-2. Duty Cycle SB-119 454-A Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and void war-ranty. Continuous Welding 100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC

Page 12 - SECTION 5 – OPERATING AUXILIARY EQUIPMENT; Standard Receptacles

OM-175 104 Page 10 SECTION 5 – OPERATING AUXILIARY EQUIPMENT 5-1. Standard Receptacles Ref. ST-178 079-A Auxiliary power decreases asweld current increases. Set Fine Adjust control R1 at10 for full auxiliary power. 1 120 V 15 A AC ReceptaclesGFCI-2 And GFCI-3 GFCI-2 and GFCI-3 supply 60 Hzsingle-pha...

Page 13 - Optional Auxiliary Power Receptacles

OM-175 104 Page 11 5-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCIreceptacles, use GFCI-pro-tected extension cord. . Auxiliary power decreases asweld current increases. Set Fine Adjust control R1 at10 for full auxiliary power. Combined output of all receptacleslimited to 8 kVA...

Page 14 - Wiring Optional 240 Volt Plug

OM-175 104 Page 12 5-3. Wiring Optional 240 Volt Plug ST-120 813-D The plug can be wired for a 240 V,2-wire load or a 120/240V, 3-wireload. See circuit diagram. 1 Plug Wired For 120/240 V,3-Wire Load When wired for 120 V loads, eachduplex receptacle shares a loadwith one half of 240 V receptacle. 2 ...

Page 15 - SECTION 6 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance

OM-175 104 Page 13 SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Recycle engine fluids. Y Stop engine before maintaining. . See also Engine Manual and mainte-nance label. Service engine more oftenif used in severe conditions. 8 h Wipe Up Spills. Check Fluid Levels. See Section...

Page 16 - Maintenance Label; KOHLER CH18 GAS ENGINE; Servicing Air Cleaner

OM-175 104 Page 14 6-2. Maintenance Label S-173 088 ° C +30 +20 +10 0 -10 -20 -30 ° F KOHLER CH18 GAS ENGINE Check 5W -20, 5W -30 0 +32 10W -30, 10W -40 +100 Recommended Oil API Service Classification SF-SG/CC-CD . . . Oil Change 100 hours . . . . . . . . . Oil Filter Change 200 hours . . . . Oil Fi...

Page 17 - Changing Engine Oil, Oil Filter, And Fuel Filter

OM-175 104 Page 15 6-4. Changing Engine Oil, Oil Filter, And Fuel Filter Ref. ST-801 188-A / Ref. ST-801 221 / Ref. ST-178 079-A / ST-800 395 / S-0842 Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter 4 Oil Fill Cap 5 Oil Dipstick Change engine oil and filter ac-cording ...

Page 18 - Adjusting Engine Speed

OM-175 104 Page 16 6-5. Adjusting Engine Speed Ref. ST-801 188-A / ST-801 209-A After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows: Start engine and run until warm.Turn Fine Adjust control to 10. Idle Speed Adjustment Move Engine Control switc...

Page 20 - Troubleshooting

OM-175 104 Page 18 6-8. Troubleshooting A. Welding Trouble Remedy No weld output. Check control settings. Check weld connections. Check fuse F1 and replace if open (see Section 6-6). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent chec...

Page 22 - SECTION 7 – ELECTRICAL DIAGRAM; Figure 7-1. Circuit Diagram For Welding Generator

OM-175 104 Page 20 SECTION 7 – ELECTRICAL DIAGRAM SB-180 690-B Figure 7-1. Circuit Diagram For Welding Generator

Page 23 - SECTION 8 – PARTS LIST

OM-175 104 Page 22 SECTION 8 – PARTS LIST 1 2 3 45 6 7 8 9 10 14 11 13 15 23 21 34 36 41 42 Fig 8-2 Fig 8-3 Figure 8-1. Main Assembly ST-801 432-B 22 16 17 18 19 20 24 25 26 27 28 29 30 31 32 33 35 37 38 39 40 12 43