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OM-405

12.16 Troubleshooting – Incomplete Fusion

Incomplete Fusion – failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes

Corrective Actions

Insufficient heat input.

Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.

12.17 Troubleshooting – Lack Of Penetration

Lack Of Penetration – shallow fusion between weld metal and
base metal.

Lack of Penetration

Good Penetration

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique.

Keep arc on leading edge of weld puddle.

Insufficient heat input.

Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

12.18 Troubleshooting – Excessive Penetration

Good Penetration

Excessive Penetration – weld metal melting through base metal and
hanging underneath weld.

Excessive Penetration

Possible Causes

Corrective Actions

Excessive heat input.

Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Содержание Bobcat 225 NT

Страница 1: ...cat 225 NT Bobcat 225 NT Processes Description OM 405 February 1997 Effective with Serial Number KH329624 Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Engine Driven Welding Genera...

Страница 2: ...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 the most out of your Miller...

Страница 3: ...ontact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Call 1 800 4 A MILLER for your local Miller distri butor Your distribu...

Страница 4: ......

Страница 5: ...ed undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable D...

Страница 6: ...weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in...

Страница 7: ...damage hearing Wear approved ear protection if noise level is high STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to...

Страница 8: ...Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological...

Страница 9: ...utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement...

Страница 10: ...r avec le plus grand soin LES BOUTEILLES peuvent exploser si elles sont endommag es Prot ger les bouteilles de gaz comprim contre la chaleur intense les chocs le laitier les flammes nues les tincelles...

Страница 11: ...A BATTERIE peut RENDRE AVEUGLE Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le moteur avant de d brancher...

Страница 12: ...ostes de soudage Elles devraient consulter leur m decin avant de s ap procher d un poste de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ou e Le bruit des processus et d...

Страница 13: ...emorque ou des blocs pour soutenir le poids Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant LIRE LES INSTRUCTIONS Utiliser uniquement des pi ces de rechang...

Страница 14: ...ions g n rales du document intitul Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publi par le Offic...

Страница 15: ...fications 3 1 Weld Power and Engine Specifications This unit uses either an Onan or a Kohler engine Differences between models are noted throughout this manual Note Welding Mode Weld Output Range Rate...

Страница 16: ...4 in 476 mm tip Depth 46 in 1164 mm D G A 18 in 457 mm 4 Holes G 25 B 16 1 2 in 419 mm E 25 C 3 4 in 19 mm F 25 25 25 D 3 1 8 in 79 mm E 32 3 4 in 832 mm Weight F 45 1 2 in 1156 mm Onan PoweredUnit 5...

Страница 17: ...13 OM 405 3 4 Fuel Consumption Onan Powered Units SB 119 455 A 3 5 Fuel Consumption Kohler Powered Units SB 179 939...

Страница 18: ...unit and void warranty 100 Duty Cycle at 225 Amperes CC AC 210 Amperes CC DC 200 Amperes CV DC 3 7 Volt Ampere Curves ST 166 024 A ST 166 025 A ST 166 026 A The volt ampere curve shows the minimum and...

Страница 19: ...1 2 Electrically bond genera tor frame to vehicle frame by metal to metal contact GND PE 3 4 2 OR OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow Clearance Loc...

Страница 20: ...ly Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil pressure gets too low Follow run in procedure in engine manual Full Full Gasoline 4 4 Connecting...

Страница 21: ...erminal for TIG welding Use Process Selector switch to select type of weld output see Section 5 1 1 Tools Needed 3 4 in 2 4 7 Selecting Weld Cable Sizes Total Cable Copper Length in Weld Circuit Not E...

Страница 22: ...tion 3 Engine Hour Meter 4 Weld Process Selector Switch Do not switch under load Use switch to select type of weld output Use a positive position for Direct Current Electrode Positive DCEP and a nega...

Страница 23: ...and one of the 120 volt recep tacles does not work 120 volts may still be present at RC1 5 Circuit Breaker CB3 6 Circuit Breaker CB4 CB3 protects RC2 and CB4 pro tects RC3 from overload If a circuit...

Страница 24: ...cords plugs etc connected to the receptacle Press button to reset receptacle and resume operation At least once a month run engine at weld power speed and press Test button to verify GFCI is working...

Страница 25: ...tacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Terminal 7 Amperes Ava...

Страница 26: ...weld terminals Clean cooling system See Engine Manual Service air cleaner wrapper foam element See Section 7 3 100 h Change oil See Section 7 5 and maintenancelabel Change oil filter See Section 7 5 a...

Страница 27: ...MILLER 064 617 Onan 140 2628 01 Air Filter Wrapper MILLER 065 653 Onan 140 1496 Spark Plug Gap 0 025 in 0 6 mm Spark Plug Champion RS17YX Preferred or RS14YC Use only resistor spark plugs and wires 0...

Страница 28: ...eplace element if dirty oily or damaged 1 2 7 4 Overload Protection Onan Powered Units ST 800 398 F Ref ST 183 175 Stop engine Disconnect negative battery cable 1 Fuse F1 See Parts List F1 protects th...

Страница 29: ...ngine 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 7 2 4 Fuel Filt...

Страница 30: ...s at idle speed see table Release governor arm Place Engine Control switch in Run Idle position 6 Carburetor Stop With solenoid energized slide sole noid until idle speed screw just touches carburetor...

Страница 31: ...nal Spark Arrestor Onan Powered Units Ref ST 801 682 A Ref ST 183 175 A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or m...

Страница 32: ...r screen See Section 8 7 Service air cleaner wrapper foam element See Section 8 3 50 h Clean and tighten weld terminals 100 h Change oil See Section 8 4 and maintenance label Check air cleaner element...

Страница 33: ...003 Gasoline Air Filter Service 100 hours or less see Owner s Manual Air Filter Element MILLER 067 272 Kohler 4708303 Air Filter Wrapper MILLER 067 273 Kohler 2408302 Spark Arrestor Inspection And Ser...

Страница 34: ...stick 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 7...

Страница 35: ...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 moun...

Страница 36: ...protects the engine wiring harness If F6 opens the engine does not crank Replace any open fuses Reinstall panel before operating unit If any fuse continues to open contact Factory Authorized Service A...

Страница 37: ...y properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check and adjust engine speed see...

Страница 38: ...Check low oil pressure shutdown switch see Parts List for location Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engin...

Страница 39: ...35 OM 405 10 Electrical Diagrams 10 1 Circuit Diagram For Welding Generator Onan Powered Units SB 180 688...

Страница 40: ...36 OM 405 10 2 Circuit Diagram For Welding Generator Kohler Powered Units SB 183 459 A...

Страница 41: ...ulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 11 2 Grounding Generator to Truck or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Termin...

Страница 42: ...tive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 11 8 3 Rating Data Rating shows volts...

Страница 43: ...e 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 Milk...

Страница 44: ...000 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 HP...

Страница 45: ...tarting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M...

Страница 46: ...nnections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or s...

Страница 47: ...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 GFCI p...

Страница 48: ...be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 12 2 4...

Страница 49: ...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 12 3...

Страница 50: ...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 12 7 Good Weld Bead Characteristics S 0...

Страница 51: ...ect Angle 12 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 weave...

Страница 52: ...12 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 for...

Страница 53: ...uses 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 before...

Страница 54: ...t from work surface before welding 12 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes C...

Страница 55: ...l and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 12 21 Troubleshooting Distortion Distortion contraction of weld met al...

Страница 56: ...un Workpiece Welding Power Source Electrode Lead Wire Feeder Work Lead Contactor 115V 24V Gas Shielding Gas Regulator Flowmeter Weld current can damage electronic parts in vehicles Disconnect both bat...

Страница 57: ...e 030 in 035 in 045 in 40 145 A 50 180 A 75 250 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 045 in 2 in per ampere 1 6 in per ampere 1 in per ampere Wire Speed 2 x 125...

Страница 58: ...m past end of nozzle and tip of wire is positioned correctly on seam Note S 0421 A 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5...

Страница 59: ...de extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Note S 0634 Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EX...

Страница 60: ...o Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 1 2 13 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Une...

Страница 61: ...iner 13 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increas...

Страница 62: ...to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire fe...

Страница 63: ...orrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 13 15 Tr...

Страница 64: ...num 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 Flat H...

Страница 65: ...61 OM 405 Notes...

Страница 66: ...List 14 1 Main Assembly Onan Engine ST 801 742 54 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 18 17 19 20 21 22 23 Fig 14 3 24 25 26 27 28 29 30 31 32 36 37 35 34 33 38 39 40 42 43 Fig 14 2 44 45 46 47 48 4...

Страница 67: ...126 Tool puller rotor Kohler 23 Fig 14 3 Generator 24 159 905 Bracket mtg engine Onan 24 173 043 Bracket mtg engine Kohler 25 167 730 Cable bat neg Onan 165 600 Cable bat neg Onan 25 082 319 Cable bat...

Страница 68: ...2 3 167 657 Receptacle str dx grd 2P3W 15A 125V 9 CB1 2 117 501 Circuit Breaker 40A 10 CB3 4 093 996 Circuit Breaker 20A 11 HM 145 247 Meter hour 12 182 870 Control push pull 13 119 014 Lever switch 1...

Страница 69: ...7 Adapter engine Onan 7 172 683 Adapter engine Kohler 8 142 156 Screw 375 16 x 1 750hexhd 9 160 573 Stud stl 375 16 x 17 125 10 125 548 Holder brush elect 11 005 614 Holder brush 12 126 984 Brush w Sp...

Страница 70: ...Notes...

Страница 71: ...Notes...

Страница 72: ...Notes...

Страница 73: ...e manufacturer s warranty if any 2 Consumable components such as contact tips cutting nozzles contactors and relays or parts that fail due to normal wear 3 Equipment that has been modified by any part...

Страница 74: ...ete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A Miller Welding Supplies and Co...

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