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Miller Electric Bobcat 225G manual

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Table of contents for the manual

  • Page 1

    OWNER’S MANUAL January 1997 Form: OM-175 104B Effective With Serial No. KG191348 cover_om 4/95 – Ref. ST -801 188-A PRINTED IN USA  1997 MILLER Electric Mfg. Co. Bobcat  225G (Kohler-Powered) CC/CV AC/DC Welding Generator For SMA W , FCA W , GMA W , GT A W Welding Welding Mode Weld Output Range Rated Welding Output Maximum Open-Circu it V[...]

  • Page 2

    OM-175 104B – 1/97 T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . .[...]

  • Page 3

    OM-175 104 Page 1 SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_rom1 4/95 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means W arning! Watch Out! possible ELECTRIC SHOCK, MOVING P ARTS, and HOT P AR TS hazards. C[...]

  • Page 4

    OM-175 104 Page 2 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 ar[...]

  • Page 5

    OM-175 104 Page 3 1-4. Additional Installation, Operation, And Maintenance Hazards MOVING P ARTS can cause injury . 1. Before working of generator , remove spark plugs or injectors to keep engine from kicking back or starting. 2. Block flywheel so that it will not turn while working on generator components. FL YING PIECES OF MET AL or DIRT can inju[...]

  • Page 6

    OM-175 104 Page 4 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator ’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check V alve Clearance Do not switch while welding W ork Connection Positive Negative Alternating Curr[...]

  • Page 7

    OM-175 104 Page 5 SECTION 3 – INST ALLA TION 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 to vehicle frame by metal-to-metal contact. GND/PE 3 4 1 Generator Base 2 Metal V ehicle Frame 3 Equipment Grounding T erminal 4 Grounding Cable Use [...]

  • Page 8

    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% DUTY CYCLE 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0[...]

  • Page 9

    OM-175 104 Page 7 3-5. Connecting The Battery Ref. ST -800 394-B / Ref. ST -178 079-A / Ref. S-0756-D + – 3/8, 1/2 in  Connect (–) cable last. T ools Needed: 3-6. W eld Output T erminals And Selecting Cable Sizes  ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, cl[...]

  • Page 10

    OM-175 104 Page 8 SECTION 4 – OPERA TING WELDING GENERA T OR 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 runs at weld/power speed.  Place swi[...]

  • Page 11

    OM-175 104 Page 9 4-2. Duty Cycle SB-1 19 454-A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void war- ranty . Continuous W elding 100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC[...]

  • Page 12

    OM-175 104 Page 10 SECTION 5 – OPERA TING AUXILIAR Y EQUIPMENT 5-1. Standard Receptacles Ref. ST -178 079-A  Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power . 1 120 V 15 A AC Receptacles GFCI-2 And GFCI-3 GFCI-2 and GFCI-3 supply 60 Hz single-phase power at weld/power speed. Maximu[...]

  • Page 13

    OM-175 104 Page 1 1 5-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord. . Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power . Combined output of all receptacles limited to 8 kV A/kW rating of the generator . 120 V olt Re[...]

  • Page 14

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

  • Page 15

    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 often if used in severe conditions. 8 h Wipe Up Spills. Check Fluid Levels. See Section 3-4. 20 h Check And Clean Optional Spark Arre[...]

  • Page 16

    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 Filter MILLER 066 698, Kohler 1205001 . . . . . . . . [...]

  • Page 17

    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 V alve 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 to engine owner ’ s manual.  Close[...]

  • Page 18

    OM-175 104 Page 16 6-5. Adjusting Engine Speed Ref. ST -801 188-A / ST -801 209-A After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. T urn Fine Adjust control to 10. Idle Speed Adjustment Move Engine Control switch to Run/Idle position. 1 Throttle Solenoi[...]

  • Page 19

    OM-175 104 Page 17 6-6. Overload Protection ST -801 226-A / Ref. ST -801 221 Y Stop engine. 1 Fuse F1 (See Parts List) F1 protects the generator excita- tion circuit. If F1 opens, there will be no/low weld and auxiliary power output. 2 Fuse F6 (See Parts List) F6 protects the engine wiring har- ness. If F6 opens, the engine does not crank. Replace [...]

  • Page 20

    OM-175 104 Page 18 6-8. T roubleshooting A. Welding T rouble 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 check brushes, slip rings, and integrated rectifier [...]

  • Page 21

    OM-175 104 Page 19 C. Engine T rouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 6-6). Check battery voltage. Check battery connections and tighten if necessary . Check plug PLG4 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine will not start. Check fuel level[...]

  • Page 22

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

  • Page 23

    OM-175 104 Page 22 SECTION 8 – P ARTS 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[...]

  • Page 24

    OM-175 104 Page 23 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 +159 907 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ +169 441 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 25

    OM-175 104 Page 24 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 44) Quantity 1 S1 162 671 SWITCH, polarity 5 position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . .[...]

  • Page 26

    OM-175 104 Page 25 Description Part No. Item No. Figure 8-3. Generator (Fig 8-1 Item 21) Quantity 1 013 367 LABEL, warning moving parts can cause serious injury 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 165 818 LABEL, warning engine fuel can cause fire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]