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Miller Electric Bobcat 225G Owner's Manual

Miller electric owner's mnaual welding generator bobcat 225g
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CC/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW Welding
Weld
Welding
Output
Mode
Range
CC/AC
50 – 225 A
CC/DC
50 – 210 A
CV/DC
17 – 28 V
cover_om 4/95 – Ref. ST-801 188-A
OWNER'S
MANUAL
Bobcat
(Kohler-Powered)
Rated
Maximum
Welding
Open-Circu
Output
it Voltage
225 A, 25 V,
100% Duty
80
Cycle
210 A, 25 V,
100% Duty
72
Cycle
200 A, 20 V,
100% Duty
33
Cycle
1997 MILLER Electric Mfg. Co.
January 1997
Effective With Serial No. KG191348
225G
Auxiliary Power
Fuel Capacity
Rating
Single-Phase,
8 kVA/kW, 70/35 A,
8.5 gal (32 L) Tank
120/240 V AC, 60 Hz
Form: OM-175 104B
Engine
Kohler CH18
Kohler CH18
Air-Cooled, Two-Cylinder,
Four-Cycle, 18 HP
Gasoline Engine
Gasoline Engine
PRINTED IN USA

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Summary of Contents for Miller Electric Bobcat 225G

  • Page 1 Maximum Auxiliary Power Open-Circu Rating it Voltage Single-Phase, 8 kVA/kW, 70/35 A, 120/240 V AC, 60 Hz 1997 MILLER Electric Mfg. Co. Form: OM-175 104B Fuel Capacity Engine Kohler CH18 Kohler CH18 Air-Cooled, Two-Cylinder, 8.5 gal (32 L) Tank Four-Cycle, 18 HP...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1-1. Symbol Usage ..............1-2.

  • Page 3: Section 1 - Safety Precautions For Arc Welding

    SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. 1-2. Arc Welding Hazards WARNING The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

  • Page 4: Engine Hazards

    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 arcs.

  • Page 5: Additional Installation, Operation, And Maintenance Hazards

    1-4. Additional Installation, Operation, And Maintenance Hazards WARNING MOVING PARTS 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.

  • Page 6: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Start Engine Engine Oil Engine Choke Positive Welding Arc (Electrode) Hours OM-175 104 Page 4 Fast Fast/Slow (Run, Weld/Power) (Run/Idle) Read Operator’s Amperes Manual Fuel Battery (Engine) Check Valve Do not switch Clearance while welding Alternating Current...

  • Page 7: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Installing Welding Generator Movement Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. 3-2. Dimensions, Weights, And Operating Angles 4 Holes Engine End ST-800 426 Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm)

  • Page 8: Fuel Consumption

    3-3. Fuel Consumption 1.67 7.57 1.46 6.62 5.67 1.25 1.04 4.73 3.78 0.84 0.63 2.84 0.42 1.89 0.95 0.21 3-4. Engine Prestart Checks Below Above 45 F (7 C) OM-175 104 Page 6 AUX POWER IDLE 2200 RPM WELD AMPERES AT 100% DUTY CYCLE POWER KVA AT 100% DUTY CYCLE Full 1/2 in...

  • Page 9: Connecting The Battery

    3-5. Connecting The Battery Tools Needed: 3/8, 1/2 in 3-6. Weld Output Terminals And Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

  • Page 10: Section 4 - Operating Welding Generator

    SECTION 4 – OPERATING WELDING GENERATOR 4-1. Front Panel Controls 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.

  • Page 11: Duty Cycle

    4-2. Duty Cycle 100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC Continuous Welding 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.

  • Page 12: Section 5 - Operating Auxiliary Equipment

    SECTION 5 – OPERATING AUXILIARY EQUIPMENT 5-1. Standard Receptacles OM-175 104 Page 10 GFCI-2 and GFCI-3 supply 60 Hz single-phase power at weld/power speed. Maximum output from each receptacle is 2.4 kVA/kW (CSA: 1.8 kVA/kW). If a ground fault is detected, Reset button pops out and the circuit opens to disconnect the faulty equipment.

  • Page 13: Optional Auxiliary Power Receptacles

    5-2. Optional Auxiliary Power Receptacles 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 kVA/kW rating of the generator.

  • Page 14: Wiring Optional 240 Volt Plug

    5-3. Wiring Optional 240 Volt Plug Current Available In Amperes 240 V Each 120 V Duplex Receptacle* Receptacle V x A = Watts *One 240 V load or two 120 V loads. Tools Needed: OM-175 104 Page 12 120V 120V 240V 240V The plug can be wired for a 240 V,...

  • Page 15: Section 6 - Maintenance And Troubleshooting

    SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Check And Clean Optional Spark Arrestor Screen. See Section 6-7. Change Oil. See Section 6-4 And Maintenance Label. Clean Cooling See Engine Change Oil Filter. See Section 6-4 And Maintenance Label. Recycle engine fluids.

  • Page 16: Maintenance Label

    6-2. Maintenance Label KOHLER CH18 GAS ENGINE See Engine Manual for complete engine care. Give engine Specification and Serial Number when ordering parts. Check daily. To Drain Oil: Push And Turn CCW 1/2 in. ID Hose Pull Recommended Oil . . . API Service Classification SF-SG/CC-CD Oil Change .

  • Page 17: Changing Engine Oil, Oil Filter, And Fuel Filter

    6-4. Changing Engine Oil, Oil Filter, And Fuel Filter Tools Needed: Ref. ST-801 188-A / Ref. ST-801 221 / Ref. ST-178 079-A / ST-800 395 / S-0842 Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Oil Fill Cap Oil Dipstick...

  • Page 18: Adjusting Engine Speed

    6-5. Adjusting Engine Speed Tools Needed: 1/4, 3/8 in OM-175 104 Page 16 2200 3700 Top View After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 50 rpm Start engine and run until warm. Turn Fine Adjust control to 10.

  • Page 19: Overload Protection

    6-6. Overload Protection 6-7. Inspecting And Cleaning Optional Spark Arrestor Tools Needed: 1/4 in Stop engine. 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. Fuse F6 (See Parts List) F6 protects the engine wiring har- ness.

  • Page 20: Troubleshooting

    6-8. Troubleshooting A. Welding Trouble 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 SR2. Check plug PLG6 connection.
  • Page 21 C. Engine Trouble 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.

  • Page 22: Section 7 - Electrical Diagram

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

  • Page 23: Main Assembly

    SECTION 8 – PARTS LIST ST-801 432-B Figure 8-1. Main Assembly OM-175 104 Page 22...
  • Page 24 Item Dia. Part Mkgs....+159 907 ....+169 441 .

  • Page 25: Panel, Front W/Components

    Item Dia. Part Mkgs....162 671 ....... .

  • Page 26: Generator

    Item Part Figure 8-3. Generator (Fig 8-1 Item 21) ..013 367 LABEL, warning moving parts can cause serious injury ..165 818 LABEL, warning engine fuel can cause fire .

This manual is also suitable for:

Bobcat 225g plus

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