Miller Electric Bobcat 225 manual Engine Troubleshooting

Page 50

 

. A complete Parts List is available at www.MillerWelds.com

 

 

Trouble

Remedy

 

 

No generator power or weld output.

Be sure all equipment is disconnected from receptacles when starting unit.

 

 

 

Check fuses F1 and F2, and replace if open (see Section 8-7or 9-6).

 

 

 

Check plug PLG6 connection.

 

 

 

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi-

 

ers SR2 and SR3.

 

 

Low power output at ac receptacles.

Check fuse F2, and replace if open (see Section 8-7or 9-6).

 

 

 

Increase Fine control R1 setting to max.

 

 

High power output at ac receptacles.

Check engine speed, and adjust if necessary (see Section 8-6or 9-5).

 

 

Erratic power output at ac receptacles.

Check fuel level.

 

 

 

Check engine speed, and adjust if necessary (see Section 8-6or 9-5).

 

 

 

Check receptacle wiring and connections.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings.

 

 

10-3. Engine Troubleshooting

Trouble

Remedy

 

 

Engine will not crank.

Check fuse F6, and replace if open (see Section 8-7or 9-6).

 

 

 

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.

Check fuel level.

 

 

 

Check battery voltage.

 

 

 

Check battery connections and tighten if necessary.

 

 

 

Check oil level (see Section 5-2or 5-3).

 

 

 

Check low oil pressure shutdown switch.

 

 

 

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8. (FS1 optional on

 

Robin-powered units.)

 

 

Engine starts but stops when Engine

Check oil level.

Control switch returns to Run position.

 

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.

 

 

 

 

Check low oil pressure shutdown switch.

 

 

Engine stopped during normal

Check fuel level.

operation.

 

 

 

 

Check oil level (see Section 5-2or 5-3).

 

 

 

Check low oil pressure shutdown switch.

 

 

 

Periodically recharge battery (approximately every 3 months).

 

 

 

Replace battery.

 

 

 

Check voltage regulator and connections according to engine manual.

 

 

 

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Robin-powered

 

units).

 

 

OM-4434 Page 46

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Contents OM-4434 File Engine DriveFrom Miller to You Table of Contents 10-3 10-110-2 11-1Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Weld, Power, and Engine Specifications − SpecificationsSymbol Definitions − DefinitionsRobin-PoweredUnit 560 lb 254 kg Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear DimensionsFuel Consumption Robin-Powered Units Fuel Consumption Kohler-Powered UnitsVolt-Ampere Curves For CC/AC ModeFor CC/DC Mode For CV/DC Mode Generator Power Curve Duty CycleMounting − InstallationInstalling Welding Generator Do not use flexible mounts GroundingOil Engine Prestart Checks Robin-Powered UnitsOil Check Engine Prestart Checks Kohler-Powered Units Connecting The Battery Connect negative − cable last Installing Exhaust PipeConnecting Or Replacing the Battery Replacing The BatteryStop engine Connecting to Weld Output TerminalsTools Needed Correct Installation Work Weld Output Terminal350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft OM-4434 Coarse Range Switch Engine Control SwitchPlace switch in Run position to operate most MIG equipment − Operating the Welding GeneratorLoaded Cold Weather Engine OperationInfrequently Frequently LoadedTypical Stick Welding Connections And Control Settings ElectrodeBe sure to use the correct size weld cables see Section Typical MIG Welding Connections And SettingsSolid Wire Applications Self-Shielded Flux Core Wire Applications Fine Control, Weld Process switch SettingsMaterial Typical Settings ForSet wire feed speed between 240-270 ipm OM-4434 Work− Operating Auxiliary Equipment Standard ReceptaclesOptional Generator Power Receptacles Breaker tripsCurrent Available in Amperes 240 Simultaneous Weld And PowerWiring Optional 240 Volt Plug Receptacle− Maintenance ROBIN-POWERED Units Maintenance Label Robin-Powered Units100 Routine Maintenance Robin-Powered UnitsStop engine before maintaining 200Stop engine and let cool Servicing Air Cleaner Robin-Powered UnitsServicing Optional Spark Arrestor Robin-Powered Units Running engine Close valve and valve capBefore adding oil Oil FillTurn idle speed screw for fine adjustments Adjusting Engine Speed Robin-Powered UnitsIdle Speed Adjustment 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 Full Before adding oil Running engine Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Adjusting Engine Speed Kohler-Powered Units Turn idle speed screw for fine ad- justmentsIf a fuse opens, it usually indi Overload Protection Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units Generator Power Troubleshooting − TroubleshootingWelding Troubleshooting Trouble RemedyEngine Troubleshooting Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare Parts− Electrical Diagrams Circuit Diagram For Welding Generator228 461-A Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack WeldsWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead − MIG Welding Gmaw Guidelines Holding And Positioning Welding GunSlow Normal Fast Push Perpendicular DragShort Normal Long Gun Movement During Welding 15-9 Troubleshooting − Excessive Penetration 15-7 Troubleshooting − Excessive Spatter15-8 Troubleshooting − Porosity Improper joint preparation Lack Of Penetration − shallowFusion between weld metal Unsteady hand Support hand on solid surface or use two hands Base metal to moveFillet Common MIG Shielding GasesApplication Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s