Miller Electric Comprehensive Troubleshooting Guide for Miller Bobcat 225 Welding Systems

6-8. Troubleshooting

A. Welding

Trouble	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.
	Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
	Check plug PLG6 connection.
Low weld output.	Check fuse F1 and replace if open (see Section 6-6).
	Check control settings.
	Check and adjust engine speed (see Section 6-5).
	Service air cleaner according to engine manual.
	Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.	Check control settings.
	Check and adjust engine speed (see Section 6-5).
Erratic weld output.	Check control settings.
	Tighten and clean connections to electrode and workpiece.
	Use dry, properly-stored electrodes for SMAW and GTAW.
	Remove excessive coils from weld cables.
	Tighten and clean connections both inside and outside welding generator.
	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 recep-	Reset circuit breakers (see Sections 5-1 and 5-2).
tacles.
	Press receptacle Reset button (see Section 5-1).
	Check fuse F1 and replace if open (see Section 6-6).
	Check plug PLG6 connection.
	Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
High power output.	Check and adjust engine speed (see Section 6-5).
Low power output.	Check fuse F1 and replace if open (see Section 6-6).
	Increase Fine Adjust control R1 setting.
Erratic power output.	Check fuel level.
	Check and adjust engine speed (see Section 6-5).
	Check receptacle wiring and connections.
	Have Factory Authorized Service Agent check brushes and slip rings.

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