Miller Electric
Bobcat 225
manual
228 461-A
Troubleshooting
Specifications
Poor Weld Bead Characteristics
Install
Parts list
Electrical Diagrams
Symbol Usage
Welding Wire can cause injury
Dimension
Replacing The Battery
Page 53
228
461-A
OM-4434
Page 49
Page 52
Page 54
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Page 52
Page 54
Contents
File Engine Drive
OM-4434
From Miller to You
Table of Contents
10-2
10-1
10-3
11-1
Arc Welding Hazards
Symbol Usage
Electric Shock can kill
HOT Parts can cause severe burns
Buildup of GAS can injure or kill
Fumes and Gases can be hazardous
ARC Rays can burn eyes and skin
Welding can cause fire or explosion
Compressed Air Hazards
Engine Hazards
HOT Parts can cause burns and injury
Welding Wire can cause injury
Fire or Explosion hazard
Falling Unit can cause injury
California Proposition 65 Warnings
Principal Safety Standards
EMF Information
Radiation can cause interference
− Consignes DE Sécurité − Lire Avant Utilisation
Signification des symboles
UN Choc Électrique peut tuer
Indique des instructions spécifiques
LE Soudage peut provoquer un in cendie ou une explosion
DES Pièces Chaudes peuvent provoquer des brûlures graves
LES 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
DES Organes Mobiles peuvent provoquer des blessures
LE Surchauffement peut endom- mager le moteur électrique
LES Fils DE Soudage peuvent provoquer des blessures
’EMPLOI Excessif peut
Information EMF
Proposition californienne 65 Avertissements
Principales normes de sécurité
Symbol Definitions
− Specifications
Weld, Power, and Engine Specifications
− Definitions
Dimensions For Units With Optional Running Gear
Dimensions, Weights, and Operating Angles
Robin-PoweredUnit 560 lb 254 kg
Dimensions
Fuel Consumption Kohler-Powered Units
Fuel Consumption Robin-Powered Units
Volt-Ampere Curves
For CC/AC Mode
For CC/DC Mode For CV/DC Mode
Duty Cycle
Generator Power Curve
Installing Welding Generator
− Installation
Mounting
Do not use flexible mounts Grounding
Oil
Engine Prestart Checks Robin-Powered Units
Oil Check
Engine Prestart Checks Kohler-Powered Units
Connecting Or Replacing the Battery
Installing Exhaust Pipe
Connecting The Battery Connect negative − cable last
Replacing The Battery
Tools Needed Correct Installation
Connecting to Weld Output Terminals
Stop engine
Work Weld Output Terminal
350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m
Selecting Weld Cable Sizes
150 ft 200 ft 250 ft
OM-4434
Place switch in Run position to operate most MIG equipment
Engine Control Switch
Coarse Range Switch
− Operating the Welding Generator
Infrequently
Cold Weather Engine Operation
Loaded
Frequently Loaded
Electrode
Typical Stick Welding Connections And Control Settings
Be sure to use the correct size weld cables see Section
Typical MIG Welding Connections And Settings
Solid Wire Applications
Fine Control, Weld Process switch Settings
Self-Shielded Flux Core Wire Applications
Set wire feed speed between 240-270 ipm OM-4434
Typical Settings For
Material
Work
Standard Receptacles
− Operating Auxiliary Equipment
Breaker trips
Optional Generator Power Receptacles
Wiring Optional 240 Volt Plug
Simultaneous Weld And Power
Current Available in Amperes 240
Receptacle
Maintenance Label Robin-Powered Units
− Maintenance ROBIN-POWERED Units
Stop engine before maintaining
Routine Maintenance Robin-Powered Units
100
200
Stop engine and let cool
Servicing Air Cleaner Robin-Powered Units
Servicing Optional Spark Arrestor Robin-Powered Units
Before adding oil
Close valve and valve cap
Running engine
Oil Fill
Idle Speed Adjustment
Adjusting Engine Speed Robin-Powered Units
Turn idle speed screw for fine adjustments
Weld/Power Speed Adjustment
Stop engine. Disconnect negative − battery cable
Overload Protection Robin-Powered Units
Maintenance Label Kohler-Powered Units
− Maintenance − KOHLER-POWERED Units
Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4434
Routine Maintenance Kohler-Powered Units
Servicing Air Cleaner Kohler−Powered Units
Full Before adding oil Running engine
Stop engine and let cool Oil Drain Valve
2 ID x 7 in Hose Oil Filter
Turn idle speed screw for fine ad- justments
Adjusting Engine Speed Kohler-Powered Units
If a fuse opens, it usually indi
Overload Protection Kohler-Powered Units
Servicing Optional Spark Arrestor Kohler-Powered Units
Welding Troubleshooting
− Troubleshooting
Generator Power Troubleshooting
Trouble Remedy
Engine Troubleshooting
Control switch S2, and throttle solenoid TS1
− Parts List
Recommended Spare Parts
Recommended Spare Parts
Circuit Diagram For Welding Generator
− Electrical Diagrams
228 461-A
Grounding Generator To Truck Or Trailer Frame
− Generator Power Guidelines
Selecting Equipment
How Much Power Does Equipment Require?
Grounding When Supplying Building Systems
Approximate Power Requirements For Farm/Home Equipment
Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Contractor Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
How Much Power Can Generator Supply?
Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x 1000 / Volts = Starting Amperage
Typical Connections To Supply Standby Power
Cord Lengths for 120 Volt Loads
Selecting Extension Cord Use Shortest Cord Possible
Current Load Watts Amperes
Cord Lengths for 240 Volt Loads
− Stick Welding Smaw Guidelines
Stick Welding Procedure
Striking an Arc − Tapping Technique
Electrode and Amperage Selection Chart
Striking an Arc − Scratch Start Technique
Good Weld Bead Characteristics
Poor Weld Bead Characteristics
Positioning Electrode Holder
10-30 9090 End View of Work Angle
Electrode Movement During Welding
Conditions That Affect Weld Bead Shape
Lap Joint
Butt Joints
Tee Joint
16 in 30 1.6 mm Tack Welds
Troubleshooting − Excessive Spatter
Troubleshooting − Porosity
Weld Test
Possible Causes Corrective Actions
Troubleshooting − Excessive Penetration
Troubleshooting − Incomplete Fusion
Troubleshooting − Lack Of Penetration
Troubleshooting − Distortion
Troubleshooting − Burn-Through
Troubleshooting − Waviness Of Bead
Holding And Positioning Welding Gun
− MIG Welding Gmaw Guidelines
Slow Normal Fast
Push Perpendicular Drag
Short Normal Long
Gun Movement During Welding
15-9 Troubleshooting − Excessive Penetration
15-7 Troubleshooting − Excessive Spatter
15-8 Troubleshooting − Porosity
Improper joint preparation
Lack Of Penetration − shallow
Fusion between weld metal
Base metal to move
Unsteady hand Support hand on solid surface or use two hands
Fillet
Common MIG Shielding Gases
Application
Page
Support
Service
Your distributor also gives
Miller Electric Mfg. Co
To locate a Distributor or Service Agency visit
For assistance in filing or settling claims, contact
Your distributor and/or equipment manufacturer’s
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