Instruction/ maintenance manual of the product Bobcat 225G Miller Electric
Go to page of 26
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.
OM-175 104B – 1/97 T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 .
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.
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 Engin.
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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 . . . . . . .
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.
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.
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.
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.
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.
OM-175 104 Page 20 SECTION 7 – ELECTRICAL DIAGRAM SB-180 690-B Figure 7-1. Circuit Diagram For W elding Generator.
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 3.
OM-175 104 Page 23 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 +159 907 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
An important point after buying a device Miller Electric Bobcat 225G (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Bobcat 225G yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Bobcat 225G - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Bobcat 225G you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Bobcat 225G will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Bobcat 225G, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Bobcat 225G.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Bobcat 225G. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Bobcat 225G along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
