Miller Electric Bobcat 225 Page 70 Owner'S Manual Download

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OM-4434 Page 66

15-3. Conditions That Affect Weld Bead Shape

Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed
(weld current), and voltage.

Short

Normal

Long

Short

Normal

Long

GUN ANGLES AND WELD BEAD PROFILES

ELECTRODE EXTENSIONS (STICKOUT)

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Push

Perpendicular

Drag

GUN TRAVEL SPEED

Slow

Normal

Fast

S-0634

Summary of Contents for Bobcat 225

Page 1: ...s Description Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 4434 218 653J 2007 11 Visit our website at www MillerWelds co...

Page 2: ...inue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get t...

Page 3: ...uel Consumption Kohler Powered Units 14 4 6 Volt Ampere Curves 15 4 7 Generator Power Curve 16 4 8 Duty Cycle 16 SECTION 5 INSTALLATION 17 5 1 Installing Welding Generator 17 5 2 Engine Prestart Check...

Page 4: ...roubleshooting 46 SECTION 11 PARTS LIST 47 11 1 Recommended Spare Parts 47 SECTION 12 ELECTRICAL DIAGRAMS 48 SECTION 13 GENERATOR POWER GUIDELINES 50 SECTION 14 STICK WELDING SMAW GUIDELINES 57 SECTIO...

Page 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Page 6: ...ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire o...

Page 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Page 8: ...ge and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield t...

Page 9: ...tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Assoc...

Page 10: ...l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises da...

Page 11: ...provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pe...

Page 12: ...oquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et s...

Page 13: ...me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut...

Page 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Page 15: ...ican National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NF...

Page 16: ...u Robin EH 65 or a Kohler CH 23 engine Differences between models are noted throughout this manual Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rati...

Page 17: ...unit where it could tip C 1 3 4 in 44 mm 4 Holes tip D 6 1 16 in 154 mm E F E 32 3 4 in 832 mm F 25 F 45 3 8 in 1153 mm 25 G 13 32 in 10 mm Dia 25 25 Weight 25 25 25 Subaru Robin PoweredUnit 560 lb 25...

Page 18: ...ect about 20 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 3 4 gal lon per hour or about 16 hours of operation 4 5 Fuel Consumption Kohler Powered Units 179 939 On a typi...

Page 19: ...Volt Ampere Curves 166 024 A 166 025 A 166 026 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fal...

Page 20: ...ows the generator power in amperes available at the receptacles Continuous Welding 4 8 Duty Cycle 119 454 A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheat...

Page 21: ...Do not install unit where air flow is restricted or engine may overheat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Term...

Page 22: ...he oil pressure shutdown system to monitor oil level Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler nec...

Page 23: ...ure shutdown system to monitor oil level Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler neck empty to a...

Page 24: ...way from exhaust outlet Point exhaust pipe in desired di rection but always away from front panel and direction of trav el Be sure to tighten exhaust clamp nuts Exhaust clamp supplied with muffler Too...

Page 25: ...ly connect weld cables may cause exces sive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied n...

Page 26: ...t use worn damaged under sized or poorly spliced cables 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 spliced cables 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2...

Page 27: ...A complete Parts List is available at www MillerWelds com OM 4434 Page 23 Notes...

Page 28: ...terval To reset cycle Engine Control switch from Run Idle to Run three times within five sec onds engine off 4 Weld Process Selector Switch NOTICE Do not switch under load Use switch to select type of...

Page 29: ...This may cause vacuum line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to...

Page 30: ...cable to Elec trode terminal on welding generator Be sure to use the correct size weld cables see Section 5 7 For best performance set the Coarse Range switch to the low est range that covers the des...

Page 31: ...terminal Be sure to use the correct size weld cables see Section 5 7 Loosen MIG gun securing knob Insert gun end through opening in feeder and position as close as possible to drive rolls without touc...

Page 32: ...n sert gun end through opening in feed er and position as close as possible to drive rolls without touching Tight en knob See wire feeder manual for wire threading procedure Insert gun trigger plug it...

Page 33: ...eld ter minal item 6 Connect work cable to welding generator Work terminal Insert trigger control plug item 11 into weld control receptacle Tighten threaded collar Connect ac power cord item 12 to 120...

Page 34: ...le phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW 4 Supplementary Protector CB1 CB1 protects receptacles RC1 RC2 and RC3 from overload If CB1 opens the receptacles do not...

Page 35: ...A kW Circuit protection is the same as standard receptacles If a ground fault is detected the GFCI Reset button pops out and the circuit opens to dis connect the faulty equipment Check for damaged too...

Page 36: ...3 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 w...

Page 37: ...A complete Parts List is available at www MillerWelds com OM 4434 Page 33 SECTION 8 MAINTENANCE SUBARU ROBIN POWERED UNITS 8 1 Maintenance Label Subaru Robin Powered Units...

Page 38: ...e Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 2 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 8 4 Spark Arrestor Screen Every 25 Hours...

Page 39: ...tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily 8 3 Servicing Air Cleaner Subaru Robin Powered Units aircleaner3 11 04 803 070 S...

Page 40: ...lter Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 5...

Page 41: ...ing Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en...

Page 42: ...low 3 Fuse F6 See Section 11 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating NOTICE If a fuse opens it...

Page 43: ...A complete Parts List is available at www MillerWelds com OM 4434 Page 39 SECTION 9 MAINTENANCE KOHLER POWERED UNITS 9 1 Maintenance Label Kohler Powered Units...

Page 44: ...Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 3 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 9 7 Spark Arrestor Screen Every 25 H...

Page 45: ...ith soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily 9 3...

Page 46: ...Filter Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section...

Page 47: ...on 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved...

Page 48: ...e F6 See Section 11 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating If a fuse opens it usually indi cate...

Page 49: ...vice air cleaner according to engine manual Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 High weld output Check control settings C...

Page 50: ...e Section 8 7 or 9 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 switc...

Page 51: ...al Engine does not return to idle speed Remove weld and generator power loads Check throttle linkage for smooth non binding operation Have Factory Authorized Service Agent check hour meter idle module...

Page 52: ...OM 4434 Page 48 SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For Welding Generator...

Page 53: ...OM 4434 Page 49 228 461 A...

Page 54: ...ctric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Groun...

Page 55: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Page 56: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Page 57: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 58: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Page 59: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Page 60: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Page 61: ...d Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Us...

Page 62: ...LET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 1...

Page 63: ...14 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 14 7 Good Weld Bead Characteristics...

Page 64: ...orrect Angle 14 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a wea...

Page 65: ...3 4 14 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be...

Page 66: ...Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface bef...

Page 67: ...dirt from work surface before welding 14 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Caus...

Page 68: ...llel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 14 21 Troubleshooting Distortion Distortion contraction of weld met...

Page 69: ...ptional gas valve Voltage Sensing Wire Feeder Constant Current CC Or Constant Voltage CV Power Source Work Lead Electrode Lead Workpiece Work Clamp Voltage Sensing Clamp Gun 802 488 15 2 Holding And P...

Page 70: ...lectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIO...

Page 71: ...Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 15 5 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Sligh...

Page 72: ...nsufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place noz...

Page 73: ...n Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pai...

Page 74: ...pport hand on solid surface or use two hands 15 14 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Page 75: ...uminum Short Circuiting Aluminum Argon All Positions5 All Positions Argon 1 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 2 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 5 O2 Fla...

Page 76: ...Notes...

Page 77: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 78: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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Miller Electric Bobcat 225, Owner'S Manual

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