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OWNER’S

MANUAL

September 1996

Form:

OM-403E

Effective With Serial No. KG220373

cover_om 4/95 – Ref. ST-800 392-C

PRINTED IN USA



1996 MILLER Electric Mfg. Co.

Bobcat



225G

(Onan-Powered)

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

Welding

Mode

Weld

Output

Range

Rated

Welding

Output

Maximum

Open-

Circuit

Voltage

Auxiliary Power

Rating

Fuel Capacity

Engine

CC/AC

50 – 225 A

225 A, 25 V,

100% Duty

Cycle

CC/DC

50 – 210 A

210 A, 25 V,

100% Duty

Cycle

Single-Phase,

8 kVA/kW, 70/35 A,

120/240 V AC, 60 Hz

8.5 gal (32 L) Tank

Onan Performer P216

Air-Cooled, Two-Cylinder,

Four-Cycle, 16 HP

Gasoline Engine

CV/DC

17 – 28 V

200 A, 20 V,

100% Duty

Cycle

Gasoline Engine

Содержание BOBCAT 225G PLUS

Страница 1: ...TAW Welding Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Auxiliary Power Rating Fuel Capacity Engine CC AC 50 225 A 225 A 25 V 100 Duty Cycle 80 CC DC 50 210 A 210 A 25 V 100 Duty Cycle 72 Single Phase 8 kVA kW 70 35 A 120 240 V AC 60 Hz 8 5 gal 32 L Tank Onan Performer P216 Air Cooled Two Cylinder Four Cycle 16 HP Gasoline Engine CV DC 17 28 V 200 A 20 V 100 Du...

Страница 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit...

Страница 3: ...Connecting The Battery 10 3 6 Weld Output Terminals And Selecting Cable Sizes 10 SECTION 4 OPERATING WELDING GENERATOR 11 4 1 Front Panel Controls 11 4 2 Duty Cycle 12 SECTION 5 OPERATING AUXILIARY EQUIPMENT 13 5 1 Standard Receptacles 13 5 2 Optional Auxiliary Power Receptacles 14 5 3 Wiring Optional 240 Volt Plug 15 SECTION 6 MAINTENANCE AND TROUBLESHOOTING 16 6 1 Routine Maintenance 16 6 2 Main...

Страница 4: ......

Страница 5: ...rsized or poorly spliced cables 11 Do not drape cables over your body 12 If earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable 13 Do not touch electrode if you are in contact with the work ground or another electrode from a different machine 14 Use only well maintained equipment Repair or replace damaged parts at once Maintain ...

Страница 6: ...s close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards 9 Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use 11 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap ...

Страница 7: ...ington 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 NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in ...

Страница 8: ...s 11 Ne pas enrouler les câbles autour du corps 12 Si la pièce soudée doit être mise à la terre le faire directement avec un câble distinct ne pas utiliser le connecteur de pièce ou le câble de retour 13 Ne pas toucher l électrode quand on est en contact avec la pièce la terre ou une électrode provenant d une autre machine 14 N utiliser qu un matériel en bon état Réparer ou remplacer sur le champ ...

Страница 9: ...s d électrocution et d incendie 9 Ne pas utiliser le chalumeau soudeur pour dégeler des tuyaux 10 Enlever l électrode enrobée du porte électrode ou couper le fil de soudage au ras du bec contact quand on ne l utilise pas 11 Porter des vêtements de protection non huileux comme des gants en cuir une chemise épaisse des pantalons sans revers des chaussures montantes et un casque 12 Ne pas porter des ...

Страница 10: ... Cutting norme ANSI Z49 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd...

Страница 11: ...V Volts Engine Oil Fuel Battery Engine Engine Engine Choke Check Valve Clearance Do not switch while welding Work Connection Positive Negative Alternating Current AC Output Gas Metal Arc Welding GMAW Wire Welding Arc Electrode Shielded Metal Arc Welding SMAW Stick Gas Tungsten Arc Welding TIG h Hours s Seconds Time Protective Earth Ground Temperature Circuit Breaker ...

Страница 12: ...n 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow Clearance Location Grounding OR Y Do Not Lift Unit From End 3 2 Dimensions Weights And Operating Angles A Dimensions B C Height 31 in 787 mm Y D Width 18 3 4 in 476 mm Y Do not exceed operating angles while run ning or engine damage will occur Y Do not move or operate unit where it could 4 Holes G Depth 46 in 1164 mm Y Do not move...

Страница 13: ...tart Checks Ref ST 800 395 A Ref ST 800 392 C Check all fluids daily 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 1 2 in 13 mm Full Gasoline ...

Страница 14: ...user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 15...

Страница 15: ...ll turning To Stop turn Engine Control switch to Off position 3 Weld Process Selector Switch Use switch to select type of weld output Use a positive position for Direct Current Electrode Positive DCEP and a negative position for Direct Current Electrode Neg ative Use AC position for alternating cur rent 4 Coarse Adjust Switch Use switch to select weld amperage range when Weld Process Selector swit...

Страница 16: ...A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating Y Exceeding duty cycle can damage unit and void warranty Continuous Welding 100 Duty Cycle at 225 Amperes AC 210 Amperes CC DC 200 Amperes CV DC ...

Страница 17: ...protects RC3 from overload If a cir cuit breaker opens the receptacle does not work 6 Circuit Breakers CB1 And CB2 CB1 and CB2 protect RC1 from overload If CB1 or CB2 opens RC1 and one of the 120 volt receptacles does not work 120 volts may still be present at RC1 If circuit breaker continues to open contact Factory Authorized Service Agent Combinedoutput of all receptacles limited to 8 kVA kW rat...

Страница 18: ...he faulty equipment Check for damaged tools 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 properly South African And Australian ReceptacleOptions 2 240 V 16 A AC South African Receptacles RC1 RC2 And RC3 3 240 V 15 A AC Australian Re ceptacles RC1...

Страница 19: ...plex receptacle 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 Available Using 120 240 V Plug 1 2 3 4 5 6 3 4 5 6 240V 240V 120V 120V One 240 V load or two 120 V loads 7 Current Available In Amperes 240 V Receptacle Each 120 V Duplex Receptacle V x A Watts...

Страница 20: ...rk Arrestor Screen See Section 6 7 50 h Clean And Tighten Weld Terminals Clean Cooling System See Engine Manual 100 h Change Oil See Section 6 4 And Maintenance Label Change Oil Filter See Section 6 4 And Maintenance Label Service Air Filter See Section 6 3 Clean And Tighten Battery Connections 200 h Replace Fuel Filter See Section 6 4 Replace Unreadable Labels Check Valve Clearance 500 h Check Sp...

Страница 21: ...ement 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 50 100 Recommended Oil API Service Classification SF SG SF CC SG CE Oil Filter Change Normal Conditions P216 100 hours P220 50 hours Oil Filter MILLER 065 251 Onan 122 0645 Oil Capacity 1 5 qt 1...

Страница 22: ...e Y Do not run engine without air cleaner or with dirty element 1 Precleaner Wash precleaner with 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 dirty or oily oil 1 2 ...

Страница 23: ...gine oil and filter accord ing to engine owner s manual Y Close valve and valve cap before adding oil and run ning engine Fill crankcase with new oil to full mark on dipstick see Section 6 2 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Y Stop engine tighten connec tions as necessary and wipe up fuel 1 2 ...

Страница 24: ...ed 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 stop Tighten solenoid mounting screws 7 Governor Arm Extension Check for smooth operation and readjust solenoid position if necessary Weld Power Speed Adjustment Place Engine Control switch in Run position 8 Weld...

Страница 25: ...ng sys tem from overload If F6 opens engine will not crank If F6 opens while engine is running weld and auxiliary power output stops Replace any open fuses Reinstall cover before operating If any fuse continues to open contact Factory Authorized Service Agent 3 8 in 1 2 6 7 Servicing Optional Spark Arrestor ST 800 395 A ST 801 206 Ref ST 178 079 A Y Stop engine and let cool 1 Spark Arrestor Screen...

Страница 26: ...workpiece Use dry properly stored electrodes for SMAW and GTAW Tighten and clean connections both inside and outside welding generator Remove excessive coils from weld cables Check and adjust engine speed see Section 6 5 Have Factory Authorized Service Agent check brushes and slip rings B Auxiliary Power Trouble Remedy No output at auxiliary power receptacles Reset circuit breakers see Section 5 1...

Страница 27: ...eck low oil pressure shutdown switch S5 see Section 3 4 and Parts List Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Have Factory Authorized Service Agent check optional fuel shutoff solenoid FS1 Battery discharges between uses Clean battery terminals and posts with baking soda and water solution rinse ...

Страница 28: ...OM 403 Page 24 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram For Welding Generator SB 180 688 ...

Страница 29: ...OM 403 Page 25 NOTES ...

Страница 30: ...e 26 SECTION 8 PARTS LIST 1 2 3 4 5 6 7 8 9 10 14 11 12 15 17 13 18 19 20 21 22 23 25 26 27 28 29 32 31 30 38 39 40 46 Fig 8 3 Fig 8 2 24 Figure 8 1 Main Assembly ST 800 815 E 33 37 36 35 34 41 42 43 44 45 16 47 ...

Страница 31: ... rotor 1 20 Fig 8 3 GENERATOR 1 21 159 905 BRACKET mtg engine 1 22 167 730 CABLE bat neg 1 165 600 CABLE bat neg 1 23 182 361 KIT hold down battery 1 24 168 385 LABEL warning battery explosion can blind 1 25 159 917 DOOR access battery 1 26 167 731 CABLE bat pos included w engine 1 27 168 037 BATTERY stor 12V 415crk 95rsv GP58 dry 1 28 159 906 PAN base 1 29 160 844 COVER base 4 30 165 660 BRACKET ...

Страница 32: ... engine parts list 1 177 859 CONNECTOR body 5 terminal 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 ST 800 816 A 16 Figure 8 2 Panel Front w Components ...

Страница 33: ...501 CIRCUIT BREAKER man reset 1P 40A 250VAC 2 10 CB3 4 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC 2 11 HM 145 247 METER hour 12 24VDC 1 12 175 010 CONTROL push pull 1 13 119 014 LEVER switch 1 14 R3 VR1 046 819 SUPPRESSOR 1 15 Work Elect 099 255 TERMINAL pwr output neutral 2 16 RC1 164 704 RECEPTACLE str 3P4W 50A 125 250V 1 17 083 030 STUD brs 250 20 x 1 750 1 18 010 915 WASHER flat 250 ID br...

Страница 34: ...hexhd 4 9 160 573 STUD stl 375 16 x 17 125 4 10 125 548 HOLDER brush elect 1 11 005 614 HOLDER brush 2 12 126 984 BRUSH w SPRING 2 13 161 306 CAP brushholder 2 14 047 879 BAR retaining brushholder 1 15 010 910 WASHER flat 406 ID stl 4 16 010 909 NUT 375 16 stl 4 17 160 943 ENDBELL consisting of 1 18 143 220 O RING 2 859 ID x 139CS 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 ST 800 798 1 14 Figure 8 ...

Страница 35: ...CC 1A 040 252 Blue CC 1C 042 360 Generic Attractive waterproof canvas covers resists stains and mildew and protect the finish of your welder Blue cover has MILLER logo and name across side VERSATILE HAND RUNNING GEAR WITH OPTIONS No 27 Running Gear has adjustable axle and choice of handles to match your job Sturdy four wheel design Standard handle designed for use on smooth surfaces and where comp...

Страница 36: ...d trailer hitches must be ordered separately Features Formed single 10 gauge sheet metal frame that decreases steps to assemble Taillights protected within channel of frame Front deck with holes for mounting a toolbox Insulated cable holders on deck for easy storage of welding cables while transporting Spring loaded license plate bracket Specifications GAWR 1300 lbs 590 kg GVWR 1300 lbs 590 kg Net...

Страница 37: ...Notes ...

Страница 38: ...Notes ...

Страница 39: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories The...

Страница 40: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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