Miller Electric Bobcat 225 10-1, 10-2, 10-3, 11-1, 15-1, 15-2, 15-3, 15-4, 15-5, 15-6, 15-7, 15-8

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TABLE OF CONTENTS


8-5.	Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)		36
8-6.	Adjusting Engine Speed (Robin-Powered Units)		37
8-7.	Overload Protection (Robin-Powered Units)		38
SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)			39
9-1.	Maintenance Label (Kohler-Powered Units)		39
9-2.	Routine Maintenance (Kohler-Powered Units)		40
9-3.	Servicing Air Cleaner (Kohler−Powered Units)		41
9-4.	Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)		42
9-5.	Adjusting Engine Speed (Kohler-Powered Units)		43
9-6.	Overload Protection (Kohler-Powered Units)		44
9-7.	Servicing Optional Spark Arrestor (Kohler-Powered Units)		44
SECTION 10 − TROUBLESHOOTING			45
10-1.	Welding Troubleshooting		45
10-2.	Generator Power Troubleshooting		45
10-3.	Engine Troubleshooting		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
SECTION 15 − MIG WELDING (GMAW) GUIDELINES			65
15-1.	Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder		65
15-2.	Holding And Positioning Welding Gun		65
15-3.	Conditions That Affect Weld Bead Shape		66
15-4.	Gun Movement During Welding		67
15-5.	Poor Weld Bead Characteristics		67
15-6.	Good Weld Bead Characteristics		67
15-7.	Troubleshooting − Excessive Spatter		68
15-8.	Troubleshooting − Porosity		68
15-9.	Troubleshooting − Excessive Penetration		68
15-10.		Troubleshooting − Lack Of Penetration	69
15-11.		Troubleshooting − Incomplete Fusion	69
15-12.		Troubleshooting − Burn-Through	69
15-13. Troubleshooting − Waviness Of Bead			70
15-14.		Troubleshooting − Distortion	70
15-15. Common MIG Shielding Gases			71
COMPLETE PARTS LIST - www.MillerWelds.com
OPTIONS AND ACCESSORIES
WARRANTY

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Contents OM-4434 File Engine DriveFrom Miller to You Table of Contents 10-1 10-210-3 11-1Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, and Operating Angles Dimensions For Units With Optional Running GearRobin-PoweredUnit 560 lb 254 kg DimensionsFuel Consumption Robin-Powered Units Fuel Consumption Kohler-Powered UnitsFor CC/DC Mode For CV/DC Mode For CC/AC ModeVolt-Ampere Curves Generator Power Curve Duty Cycle− Installation Installing Welding GeneratorMounting Do not use flexible mounts GroundingOil Check Engine Prestart Checks Robin-Powered UnitsOil Engine Prestart Checks Kohler-Powered Units Installing Exhaust Pipe Connecting Or Replacing the BatteryConnecting The Battery Connect negative − cable last Replacing The BatteryConnecting to Weld Output Terminals Tools Needed Correct InstallationStop engine Work Weld Output Terminal150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m OM-4434 Engine Control Switch Place switch in Run position to operate most MIG equipmentCoarse Range Switch − Operating the Welding GeneratorCold Weather Engine Operation InfrequentlyLoaded Frequently LoadedTypical Stick Welding Connections And Control Settings ElectrodeSolid Wire Applications Typical MIG Welding Connections And SettingsBe sure to use the correct size weld cables see Section Self-Shielded Flux Core Wire Applications Fine Control, Weld Process switch SettingsTypical Settings For Set wire feed speed between 240-270 ipm OM-4434Material Work− Operating Auxiliary Equipment Standard ReceptaclesOptional Generator Power Receptacles Breaker tripsSimultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle− Maintenance ROBIN-POWERED Units Maintenance Label Robin-Powered UnitsRoutine Maintenance Robin-Powered Units Stop engine before maintaining100 200Servicing Optional Spark Arrestor Robin-Powered Units Servicing Air Cleaner Robin-Powered UnitsStop engine and let cool Close valve and valve cap Before adding oilRunning engine Oil FillAdjusting Engine Speed Robin-Powered Units Idle Speed AdjustmentTurn idle speed screw for fine adjustments Weld/Power Speed AdjustmentOverload Protection Robin-Powered Units Stop engine. Disconnect negative − battery cable− Maintenance − KOHLER-POWERED Units Maintenance Label Kohler-Powered UnitsRoutine Maintenance Kohler-Powered Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4434Servicing Air Cleaner Kohler−Powered Units 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveFull Before adding oil Running engine Adjusting Engine Speed Kohler-Powered Units Turn idle speed screw for fine ad- justmentsServicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi − Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting − Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts− Electrical Diagrams Circuit Diagram For Welding Generator228 461-A Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesStriking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion − MIG Welding Gmaw Guidelines Holding And Positioning Welding GunShort Normal Long Push Perpendicular DragSlow Normal Fast Gun Movement During Welding 15-8 Troubleshooting − Porosity 15-7 Troubleshooting − Excessive Spatter15-9 Troubleshooting − Excessive Penetration Fusion between weld metal Lack Of Penetration − shallowImproper joint preparation Unsteady hand Support hand on solid surface or use two hands Base metal to moveApplication Common MIG Shielding GasesFillet Page Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s