Maintenance − KOHLER-POWERED Units | Miller Electric Bobcat 225

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

SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)

9-1. Maintenance Label (Kohler-Powered Units)

OM-4434 Page 39

Page 43

Image 43

Miller Electric Bobcat 225 manual Maintenance − KOHLER-POWERED Units, Maintenance Label Kohler-Powered Units

Contents

File Engine Drive OM-4434 From Miller to You Table of Contents 11-1 10-110-2 10-3 HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LES 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 ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine Specifications Dimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Robin-PoweredUnit 560 lb 254 kg Fuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered Units For CC/DC Mode For CV/DC Mode For CC/AC ModeVolt-Ampere Curves Duty Cycle Generator Power Curve Do not use flexible mounts Grounding − InstallationInstalling Welding Generator Mounting Oil Check Engine Prestart Checks Robin-Powered UnitsOil Engine Prestart Checks Kohler-Powered Units Replacing The Battery Installing Exhaust PipeConnecting Or Replacing the Battery Connecting The Battery Connect negative − cable last Work Weld Output Terminal Connecting to Weld Output TerminalsTools Needed Correct Installation Stop engine 150 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 − Operating the Welding Generator Engine Control SwitchPlace switch in Run position to operate most MIG equipment Coarse Range Switch Frequently Loaded Cold Weather Engine OperationInfrequently Loaded Electrode Typical Stick Welding Connections And Control Settings Solid Wire Applications Typical MIG Welding Connections And SettingsBe sure to use the correct size weld cables see Section Fine Control, Weld Process switch Settings Self-Shielded Flux Core Wire Applications Work Typical Settings ForSet wire feed speed between 240-270 ipm OM-4434 Material Standard Receptacles − Operating Auxiliary Equipment Breaker trips Optional Generator Power Receptacles Receptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240 Maintenance Label Robin-Powered Units − Maintenance ROBIN-POWERED Units 200 Routine Maintenance Robin-Powered UnitsStop engine before maintaining 100 Servicing Optional Spark Arrestor Robin-Powered Units Servicing Air Cleaner Robin-Powered UnitsStop engine and let cool Oil Fill Close valve and valve capBefore adding oil Running engine Weld/Power Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsIdle Speed Adjustment Turn idle speed screw for fine adjustments 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 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveFull Before adding oil Running engine Turn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power Troubleshooting Engine Troubleshooting Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare Parts Circuit Diagram For Welding Generator − Electrical Diagrams 228 461-A Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building Systems Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes − Stick Welding Smaw Guidelines Stick Welding Procedure Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape 16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Holding And Positioning Welding Gun − MIG Welding Gmaw Guidelines Short 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 Base metal to move Unsteady hand Support hand on solid surface or use two hands Application Common MIG Shielding GasesFillet Page Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact