Main
Bobcat 225
Processes
Description
From Miller to You
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TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
1-1. Symbol Usage
1-2. Arc Welding Hazards
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in inverters after stop- ping engine.
FUMES AND GASES can be hazardous.
BUILDUP OF GAS can injure or kill.
ARC RAYS can burn eyes and skin.
WELDING can cause fire or explosion.
NOISE can damage hearing.
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND.
FUEL can cause fire or explosion.
MOVING PARTS can cause injury.
HOT PARTS can cause severe burns.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
FALLING UNIT can cause injury.
OVERHEATING can damage motors.
FLYING SPARKS can cause injury.
1-6. California Proposition 65 Warnings
1-7. Principal Safety Standards
1-8. EMF Information
SECTION 2 UTILISATION
2-1. Signification des symboles
2-2. Dangers relatifs au soudage larc
UN CHOC LECTRIQUE peut tuer.
Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
DES PICES CHAUDES peuvent provoquer des brlures graves.
e
DES PIECES DE METAL ou DES SA- LETES peuvent provoquer des bles- sures dans les yeux.
LES FUMES ET LES GAZ peuvent tr
2-3. Dangers existant en relation avec le moteur
LEXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE.
LE CARBURANT MOTEUR peut prov
quer un incendie ou une explosion.
DES ORGANES MOBILES peuvent pr o
2-4. Dangers lis lair comprim
RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort.
LAIR COMPRIM peut provoquer des blessures.
LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures.
Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion.
LE SURCHAUFFEMENT peut endom- mager le moteur lectrique.
LES TINCELLES VOLANTES ris- quent de provoquer des blessures.
DES ORGANES MOBILES peuvent provoquer des blessures.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.
2-6. Proposition californienne 65 Avertissements
2-7. Principales normes de scurit
2-8. Information EMF
Des implants mdicaux :
SECTION 3 DEFINITIONS
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3-1. Symbol Definitions
SECTION 4 SPECIFICATIONS
4-1. Weld, Power, and Engine Specifications
4-2. Dimensions, Weights, and Operating Angles
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B
C
4-3. Dimensions For Units With Optional Running Gear
4-4. Fuel Consumption (Robin-Powered Units)
4-5. Fuel Consumption (Kohler-Powered Units)
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SECTION 5 INSTALLATION
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5
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-1. Installing Welding Generator
5-2. Engine Prestart Checks (Robin-Powered Units)
5-3. Engine Prestart Checks (Kohler-Powered Units)
5-4. Installing Exhaust Pipe
5-5. Connecting Or Replacing the Battery
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5-6. Connecting to Weld Output Terminals
5-7. Selecting Weld Cable Sizes*
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Pros weld and cut safely. Read the safety rules at the beginning of this manual.
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SECTION 6 OPERATING THE WELDING GENERATOR
6-1. Front Panel Controls
6-2. Cold Weather Engine Operation
6-3. Typical Stick Welding Connections And Control Settings
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6-4. Typical MIG Welding Connections And Settings
A. Solid Wire Applications
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B. Self-Shielded Flux Core Wire Applications
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6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun
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SECTION 7 OPERATING AUXILIARY EQUIPMENT
7-1. Standard Receptacles
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7-3. Simultaneous Weld And Power
7-4. Wiring Optional 240 Volt Plug
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8-2. Routine Maintenance (Robin-Powered Units)
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8-3. Servicing Air Cleaner (Robin-Powered Units)
8-4. Servicing Optional Spark Arrestor (Robin-Powered Units)
8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)
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8-6. Adjusting Engine Speed (Robin-Powered Units)
8-7. Overload Protection (Robin-Powered Units)
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9-2. Routine Maintenance (Kohler-Powered Units)
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9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)
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9-5. Adjusting Engine Speed (Kohler-Powered Units)
9-6. Overload Protection (Kohler-Powered Units)
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9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units)
SECTION 10 TROUBLESHOOTING
10-1. Welding Troubleshooting
10-2. Generator Power Troubleshooting
10-3. Engine Troubleshooting
SECTION 11 PARTS LIST
11-1. Recommended Spare Parts
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SECTION 13 GENERATOR POWER GUIDELINES
13-1. Selecting Equipment
13-2. Grounding Generator To Truck Or Trailer Frame
13-3. Grounding When Supplying Building Systems
13-4. How Much Power Does Equipment Require?
13-5. Approximate Power Requirements For Industrial Motors
13-6. Approximate Power Requirements For Farm/Home Equipment
13-7. Approximate Power Requirements For Contractor Equipment
13-8. Power Required To Start Motor
13-9. How Much Power Can Generator Supply?
13-10. Typical Connections To Supply Standby Power
13-11. Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 14 STICK WELDING (SMAW) GUIDELINES
14-1. Stick Welding Procedure
OM-4434 Page 58
14-2. Electrode and Amperage Selection Chart
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3
14-3. Striking an Arc Scratch Start Technique
1 2 3
14-5. Positioning Electrode Holder
14-6. Poor Weld Bead Characteristics
14-7. Good Weld Bead Characteristics
14-8. Conditions That Affect Weld Bead Shape
14-9. Electrode Movement During Welding
14-10. Butt Joints
14-11. Lap Joint
14-12. Tee Joint
14-13. Weld Test
14-14. Troubleshooting Porosity
14-15. Troubleshooting Excessive Spatter
14-16. Troubleshooting Incomplete Fusion
14-17. Troubleshooting Lack Of Penetration
14-18. Troubleshooting Excessive Penetration
14-19. Troubleshooting Burn-Through
14-20. Troubleshooting Waviness Of Bead
14-21. Troubleshooting Distortion
SECTION 15 MIG WELDING (GMAW) GUIDELINES
15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder
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15-2. Holding And Positioning Welding Gun
15-3. Conditions That Affect Weld Bead Shape
15-4. Gun Movement During Welding
15-5. Poor Weld Bead Characteristics
15-6. Good Weld Bead Characteristics
15-7. Troubleshooting Excessive Spatter
15-8. Troubleshooting Porosity
15-9. Troubleshooting Excessive Penetration
15-10. Troubleshooting Lack Of Penetration
15-11. Troubleshooting Incomplete Fusion
15-12. Troubleshooting Burn-Through
15-13. Troubleshooting Waviness Of Bead
15-14. Troubleshooting Distortion
15-15. Common MIG Shielding Gases
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Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Effective January 1, 2007 (Equipment with a serial number preface of LH or newer)
Please complete and retain with your personal records.
For Service
Always provide Model Name and Serial/Style Number.
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Owners Record