Miller Electric Bobcat 225G User Manual

January 1997 Form: OM-175 104B

Gasoline Engine

Effective With Serial No. KG191348

OWNER’S

MANUAL

Welding

Mode

CC/AC 50

CC/DC

CV/DC

cover_om 4/95 – Ref. ST-801 188-A PRINTED IN USA

Bobcat 225G

(Kohler-Powered)

CC/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW Welding

Weld

Output

Range

– 225 A

50 – 210 A

17 – 28 V

Rated

Welding

Output

225 A, 25 V

100% Duty

Cycle

210 A, 25 V

100% Duty

Cycle

200 A, 20 V

100% Duty

Cycle

Maximum

Open-Circu

it Voltage

Auxiliary Power

Rating

Single-Phase,

8 kVA/kW

120/240 V AC, 60 Hz

 1997 MILLER Electric Mfg. Co.

, 70/35 A,

Fuel Capacity Engine

8.5 gal (32 L) T

ank

Kohler CH18

Air-Cooled, T

Four-Cycle, 18 HP

Gasoline Engine

wo-Cylinder,

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1.

1-1. Symbol Usage 1. 1-2. Arc Welding Hazards 1. 1-3. Engine Hazards 2. 1-4. Additional Installation, Operation, And Maintenance Hazards 3. 1-5. Principal Safety Standards 3. 1-6. EMF Information 3.

SECTION 2 – DEFINITIONS 4.

2-1. Symbol Definitions 4.

SECTION 3 – INSTALLATION 5.

3-1. Installing Welding Generator 5. 3-2. Dimensions, Weights, And Operating Angles 5. 3-3. Fuel Consumption 6. 3-4. Engine Prestart Checks 6. 3-5. Connecting The Battery 7. 3-6. Weld Output Terminals And Selecting Cable Sizes 7.

SECTION

4 – OPERA

4-1. Front Panel Controls 8. 4-2. Duty Cycle 9.

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TING WELDING GENERATOR 8.

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SECTION

SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 13.

SECTION 7 – ELECTRICAL DIAGRAM 20. SECTION 8 – PARTS LIST 21.

5 – OPERA

5-1. Standard Receptacles 10. 5-2. Optional Auxiliary Power Receptacles 11. 5-3. Wiring Optional 240 Volt Plug 12.

6-1. Routine Maintenance 13. 6-2. Maintenance Label 14. 6-3. Servicing Air Cleaner 14. 6-4. Changing Engine Oil, Oil Filter, And Fuel Filter 15. 6-5. Adjusting Engine Speed 16. 6-6. Overload Protection 17. 6-7. Inspecting And Cleaning Optional Spark Arrestor 17. 6-8. Troubleshooting 18

TING AUXILIAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Y EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10.

OM-175 104B – 1/97

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING

safety_rom1 4/95

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure!

The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING

and HOT PARTS hazards. Consult symbols and related instructions below for necessary

PARTS, actions

to avoid the hazards.

1-2. Arc Welding Hazards

WARNING

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away.

Marks a special safety message.

Means NOTE; not safety related.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit

is electrically live whenever the The input power circuit and machine internal circuits are also live when power is on. In semiautomatic wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment

Do not touch live electrical parts.

2. W

ear dry

, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any

the

work or ground.

4. Disconnect input power or stop engine before installing or servicing to

5. Properly install and ground this equipment according to its Owner’s

6. Always power cord ground wire is properly connected to ground

this equipment. Lockout/tagout input power

OSHA 29 CFR 1910.147 (see Safety Standards).

Manual and national, state, and local codes.

verify the supply ground – check and be

or automatic wire welding, the wire,

is a hazard.

output is on.

physical contact with

according

sure that input

ARC RAYS can burn eyes and skin; NOISE can damage hearing; FLYING SLAG OR SPARKS can injure eyes.

Arc

rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding, and welds cooling throw off pieces of metal

NOISE

Use approved ear plugs or ear muf

or slag.

fs if noise level is high.

terminal in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

7. When making input connections, attach proper grounding conductor

8. Frequently replace

9. T

urn of

10. Do not use worn, damaged, undersized, or poorly spliced cables.

11. Do

earth grounding of the workpiece is required,

12. If with

13. Do not touch electrode if you are in contact with the work, ground,

14. Use only well-maintained equipment. Repair or replace damaged

15. W

16.

Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to workpiece

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to protect Z49.1

3. W

4. Use protective screens or barriers to protect others from flash and

5. Wear protective clothing made from durable, flame-resistant material

first – double-check connections.

inspect input power cord for damage or bare wiring –

cord immediately if damaged – bare wiring can kill.

f all equipment when not in use.

not drape cables over your body

a separate cable – do not use work clamp or work cable.

or another electrode from a dif

parts at once. Maintain unit according to manual.

ear a safety harness if working above floor level.

or worktable as near the weld as practical.

your face and eyes when welding or

and Z87.1 listed in Safety Standards).

ear approved safety glasses with side shields.

glare; warn others not to watch the arc.

(wool and leather) and foot protection.

ground it directly

ferent machine.

watching (see ANSI

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep

2. If inside, ventilate the area and/or use exhaust at the arc to

4. Read the Material Safety Data Sheets (MSDSs) and the

your head out of the fumes. Do not breathe the fumes.

remove

welding fumes and gases.

If ventilation is poor

manufacturer’s instruction for metals, consumables, coatings, cleaners,

and degreasers.

, use an approved air-supplied respirator

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson and

lower the oxygen level

breathing

6. Do

not weld operations. form

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing containing

nearby

. W

elding fumes and gases can displace air

air is safe.

in locations near degreasing, cleaning, or spraying

The

highly toxic and irritating gases.

heat and rays of the arc can react with vapors to

an air-supplied respirator

these elements can give of

causing injury or death. Be sure the

. The coatings and any

f toxic fumes if welded.

OM-175 104 Page 1

metals

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process,

be sure to treat them carefully

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.

2. Install

3. Keep cylinders away from any welding or other electrical

cylinders in an upright position by securing

support

or cylinder rack to prevent falling or tipping.

circuits.

to a stationary

4. Never

7. Use

8. Turn

9. Keep

10. Read and follow instructions on compressed gas cylinders,

drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder – explosion will result.

only correct shielding gas cylinders, regulators, hoses, and

fittings

designed for the specific application; maintain them and

associated

use or connected for use.

associated Standards.

parts in good condition.

face away from valve outlet when opening cylinder valve.

protective cap in place over valve except when cylinder is

equipment, and CGA publication P-1

listed in Safety

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment and

burns. Accidental contact of electrode to

objects

can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing

any welding.

Protect yourself and others from flying sparks and hot metal.

2. Do

not weld where flying sparks can strike flammable material.

3. Remove

4. Be

5. Watch

all flammables within

this

is not possible, tightly cover them with approved covers.

alert that welding sparks and hot materials from welding can

easily go

through

small cracks and openings to adjacent areas.

for fire, and keep a fire extinguisher nearby

35 ft (10.7 m) of the welding arc. If

1-3. Engine Hazards

WARNING

ENGINE EXHAUST GASES can kill.

Engines

produce harmful exhaust gases.

ENGINE FUEL can cause fire or explosion.

Engine

fuel is highly flammable.

1. Stop

engine and let it cool of

f before checking or adding fuel.

can cause fires

metal

aware that welding on a ceiling, floor

6. Be can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to A

(see

Safety Standards).

8. Connect

10. Remove stick electrode from holder or cut off welding wire at

11. Wear

12. Remove

2. If used in a closed area, vent engine exhaust outside and

2. Do

4. Do not spill fuel. If fuel is spilled, clean up before starting

work cable to

practical

to prevent welding current from

unknown Do not use welder to thaw frozen pipes.

contact

shirt, cuf

from

paths and causing electric shock and fire hazards.

tip when not in use.

oil-free protective garments such as leather gloves,

fless trousers, high shoes, and a cap. any combustibles,

your person before doing any welding.

Use equipment outside in open, well-ventilated areas.

from any building air intakes.

away

not add fuel while smoking or

open

flames.

Do not overfill tank – allow room for fuel to expand.

engine.

the work as close to the welding area as

such as a butane lighter or matches,

, bulkhead, or partition

WS F4.1

traveling long, possibly

heavy

if unit is near any sparks or

MOVING PARTS can cause injury.

Moving

parts, such as fans, rotors, and belts can

cut

fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and

in place.

securely Stop engine before installing or connecting unit.

SPARKS

can cause BA

TTERY

GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

It is best to check coolant level when engine is cold

to avoid scalding.

OM-175 104 Page 2

3. Have only qualified people remove guards or covers for maintenance

4. To prevent accidental starting during servicing, disconnect negative

5. Keep parts.

6. Reinstall finished

1. Always

2. Stop engine before disconnecting or connecting battery cables.

not allow tools to cause sparks when working on a battery

3. Do

not

4. Do

5. Observe

1. If

the engine is warm and checking

and

2. W

ear safety glasses and gloves and put a rag over cap.

3. Turn cap slightly and let pressure escape slowly before completely

and troubleshooting as necessary

(–) battery cable from battery

hands, hair

and before starting engine.

wear a face shield when working on a battery

use welder to charge batteries or jump start vehicles.

, loose clothing, and tools away from

panels or

correct polarity (+ and –) on batteries.

guards and close doors when servicing is

removing cap.

is needed, follow steps 2

moving

1-4. Additional Installation, Operation, And Maintenance Hazards

WARNING

MOVING PARTS can cause injury.

1. Before

2. Block

working or injectors to keep engine from kicking back or starting.

flywheel so that it will not

generator components.

of generator

, remove spark plugs

turn while working

FLYING PIECES OF METAL or DIRT can injure eyes.

1. Wear safety glasses with side shields or face shield.

STATIC ELECTRICITY can damage parts on circuit boards.

1. Put on grounded wrist strap BEFORE handling boards

or parts.

2. Use proper static-proof bags and boxes to store,

or ship PC boards.

move,

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

1. Pacemaker wearers keep away.

earers should consult their doctor before going

2. W near arc welding, gouging, or spot welding operations.

HOT PARTS can cause severe burns.

1. .Allow

2. Wear

cooling period before maintaining.

protective gloves and clothing when working

a hot engine.

READ INSTRUCTIONS.

1. Use

only genuine MILLER replacement parts.

2. Reinstall injectors and bleed air from fuel system according to engine manual.

DO NOT LET ENGINE EXHAUST SPARKS CAUSE FIRE.

1. Use approved engine exhaust spark arrestor in

areas – see applicable codes.

required

LOW VOLTAGE AND FREQUENCY CAN DAMAGE electrical equipment such as MOTORS.

1. Turn off or unplug equipment before starting or stopping

engine.

OVERUSE can cause OVERHEATED EQUIPMENT.

1. Allow

2. Reduce current or reduce duty cycle before

cooling period.

starting

to weld again.

Follow rated duty cycle.

TILTING OF TRAILER can cause injury.

1. Use

tongue jack or blocks to support weight.

2. Properly install welding generator onto trailer according

to instructions supplied with trailer

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

1. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift unit.

1-5. Principal Safety Standards

Safety

in W

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

elding and Cutting

Safety and Health Standards

Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances

American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code

Protection Association, Batterymarch Park, Quincy, MA 02269.

, ANSI Standard

, OSHA 29 CFR 1910, from

, NFPA Standard 70, from National Fire

Z49.1, from American

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

The

following

the U.S. Congress, Office of Technology Assessment,

Effects Paper

Office, findings with animals and people which clearly establish that low frequency magnetic systems. complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

is a quotation from the General Conclusions Section of

of Power Frequency Electric & Magnetic Fields – Background

, OTA-BP-E-53 (Washington, DC: U.S. Government Printing

May 1989): “. . . there is now a

based on experiments at the cellular level and from studies

fields can

While most of this work is of very high quality

interact with, and produce changes in, biological

it does not yet allow us to draw definite conclusions about

very large volume of scientific

Biological

, the results are

BATTERY ACID can BURN SKIN AND EYES.

1. Do

not tip.

Replace damaged battery

Flush eyes and skin immediately with water

Safe Handling of Compressed Gases in Cylinders

P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code

for Safety in W

Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

afe Practices For Occupation And Educational Eye And Face

Protection

Institute, 1430 Broadway, New York, NY 10018.

Cutting

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as

5. Connect work clamp to workpiece as close to the weld as

About Pacemakers:

The above procedures are also recommended for pacemaker wearers. Consult your doctor for complete information.

ANSI Standard Z87.1, from American National Standards

And

practical.

possible.

elding and

elding Processes

Cutting

, NFP

, CGA Pamphlet

, CSA Standard W1

A Standard 51B, from National

17.2, from

OM-175 104 Page 3

2-1. Symbol Definitions

SECTION 2 – DEFINITIONS

Stop

Engine

Start Engine

Engine Oil

Engine Choke

Positive Negative

elding Arc

(Electrode)

Hours

(Run, W

Read Operator

Check Valve

Clearance

Gas Metal Arc elding (GMA

Seconds Time

Fast

eld/Power)

Manual

Fuel

Wire

W),

Fast/Slow (Run/Idle)

’s

Amperes

Battery (Engine)

Do not switch while welding

Alternating Current

(AC)

Shielded Metal Arc

elding (SMA

W),

Stick

Slow (Idle)

Volts

Engine

ork Connection

Output

Gas T

ungsten Arc

elding (TIG)

Protective Earth

(Ground)

Temperature Circuit Breaker

OM-175 104 Page 4

SECTION 3 – INSTALLATION

 Do not exceed operating angles while

3-1. Installing Welding Generator

Movement Airflow Clearance Location

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Grounding

Electrically

bond

generator frame to

GND/PE

vehicle frame by metal-to-metal

contact.

3-2. Dimensions, Weights, And Operating Angles

4 Holes

Height

Width

Depth

Dimensions

31 in (787 mm)

18-3/4 in (476 mm)

46 in (1

164 mm)

18 in

(460 mm)

1 Generator Base 2

Metal V

ehicle Frame

install1* 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

 Do not exceed operating angles while

running

 Do

not move or operate unit where it could

tip.

Equipment Grounding Terminal

Grounding Cable

Use #10 AWG or larger insulated

wire.

copper

or engine damage will occur

Engine End

ST-800 426

18 in (457 mm)

16-1/2 in (419 mm)

3/4 in (19 mm)

3-1/8 in (79 mm)

32-3/4 in (832 mm)

45-1/2 in (1

13/32 in (10 mm) Dia.

156 mm)

25° 25°

Weight

Net: 567 lb (258 kg)

Ship: 608 lb (276 kg)

OM-175 104 Page 5

25°

angles_1 3/96

3-3. Fuel Consumption

7.57

6.62

5.67

4.73

3.78

2.84

1.89

0.95

LITERS/HR.

1.67

1.46

1.25

1.04

0.84

0.63

0.42

0.21

IMP. GAS/HR.

2.0

1.8

1.5

1.3

1.0

0.8

0.5

0.3

0.0 0 25 50 75 100 125 150 175 200 225 250 275

U.S. GAL/HR.

0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

3-4. Engine Prestart Checks

IDLE

2200 RPM

AUX POWER

3750 RPM

CV WELD 3750 RPM

WELD AMPERES AT 100% DUTY CYCLE

POWER KVA AT 100% DUTY CYCLE

Full

DC WELD

AC WELD 3750 RPM

Ref. SB-179 939

Check

all fluids daily

cold and on a level surface. Unit

shipped with 10W30 engine oil.

Low Oil Pressure Shutdown Switch

Engine stops if oil pressure gets

low

too 2

Anti-Icing Control

Use control to prevent carburetor

in cold weather

icing

. Engine must

Below Above

45°F

(7°C)

1/2 in

(13 mm)

Full

Gasoline

OM-175 104 Page 6

Ref. ST-801 188-A / Ref. ST-801 221

+ 18 hidden pages

Miller Electric Bobcat 225G User Manual

TABLE OF CONTENTS

1-1. Symbol Usage

1-2. Arc Welding Hazards

1-3. Engine Hazards

1-4. Additional Installation, Operation, And Maintenance Hazards

1-5. Principal Safety Standards

1-6. EMF Information

2-1. Symbol Definitions

3-1. Installing Welding Generator

3-2. Dimensions, Weights, And Operating Angles

3-3. Fuel Consumption

3-4. Engine Prestart Checks