Miller BOBCAT 225G PLUS Owner's Manual
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Miller BOBCAT 225G PLUS Owner's Manual

Miller BOBCAT 225G PLUS Owner's Manual

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CC/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW Welding
Weld
Welding
Output
Mode
Range
CC/AC
50 – 225 A
CC/DC
50 – 210 A
CV/DC
17 – 28 V
cover_om 4/95 – Ref. ST-800 392-C
OWNER'S
MANUAL
Bobcat 225G
(Onan-Powered)
Maximum
Rated
Open-
Welding
Circuit
Output
Voltage
225 A, 25 V,
100% Duty
80
Cycle
210 A, 25 V,
100% Duty
72
Cycle
200 A, 20 V,
100% Duty
33
Cycle
1996 MILLER Electric Mfg. Co.
September 1996 Form: OM-403E
Effective With Serial No. KG220373
Auxiliary Power
Fuel Capacity
Rating
Single-Phase,
8 kVA/kW, 70/35 A,
8.5 gal (32 L) Tank
120/240 V AC, 60 Hz
Engine
Onan Performer P216
Air-Cooled, Two-Cylinder,
Four-Cycle, 16 HP
Gasoline Engine
Gasoline Engine
PRINTED IN USA

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  • Page 1 Four-Cycle, 16 HP Cycle 120/240 V AC, 60 Hz Gasoline Engine Gasoline Engine 200 A, 20 V, 100% Duty CV/DC 17 – 28 V Cycle  1996 MILLER Electric Mfg. Co. cover_om 4/95 – Ref. ST-800 392-C PRINTED IN USA...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING ....... . 1-1.

  • Page 5: Section 1 - Safety Precautions For Arc Welding

    SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_rom1 4/95 1-1. Symbol Usage Y Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

  • Page 6: Engine Hazards

    4. Never drape a welding torch over a gas cylinder. CYLINDERS can explode if damaged. 5. Never allow a welding electrode to touch any cylinder. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since 6.

  • Page 7: Additional Installation, Operation, And Maintenance Hazards

    MOVING PARTS can cause injury. READ INSTRUCTIONS. 1. Before working of generator, remove spark plugs or 1. Use only genuine MILLER replacement parts. injectors to keep engine from kicking back or 2. Reinstall injectors and bleed air from fuel system starting.

  • Page 8: Signification Des Symboles

    SECTION 1 – CONSIGNES DE SÉCURITÉ POUR LE SOUDAGE À L’ARC safety_rom1_fr 4/95 1-1. Signification des symboles Signifie Mise en garde! Soyez vigilant! Cette procédure présente des Identifie un message de sécurité particulier. risques de danger! Ceux-ci sont identifiés par des symboles adjacents aux Signifie NOTA;...
  • Page 9 LES BOUTEILLES peuvent exploser si elles 4. Ne jamais poser un chalumeau soudeur sur une bouteille de gaz. sont endommagées. 5. Ne jamais laisser une électrode de soudage toucher une bouteille. Les bouteilles contenant des gaz de protection sont à haute 6.
  • Page 10 LIRE LES INSTRUCTIONS. Les personnes qui portent un stimulateur cardiaque Utiliser uniquement des pièces de rechange MILLER. doivent se tenir éloignées des postes de soudage. Réinstaller les injecteurs et évacuer l’air du système de Elles devraient consulter leur médecin avant de carburant selon le manuel du moteur.

  • Page 11: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch while Engine Choke Work Connection Clearance welding Alternating Current Positive...

  • Page 12: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Installing Welding Generator Movement Airflow Clearance Location Y Do Not Lift Unit From End 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) Grounding Generator Base Metal Vehicle Frame Equipment Grounding...

  • Page 13: Fuel Consumption

    3-3. Fuel Consumption SB-119 455-A 3-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure gets too low. Follow run-in procedure in 1/2 in engine manual.

  • Page 14: Connecting The Battery

    3-5. Connecting The Battery Y Connect (–) cable last. – 3/8, 1/2 in Ref. ST-800 394-B / Ref. ST-178 079-A / Ref. S-0756-D 3-6. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment.

  • Page 15: Section 4 - Operating Welding Generator

    SECTION 4 – OPERATING WELDING GENERATOR 4-1. Front Panel Controls Ref. ST-178 079-A Engine Control Switch gine starts. Do not crank engine if engine is Use switch to select weld amperage range still turning. when Weld Process Selector switch is in Use switch to start engine, select speed, and Stick/Tig position, or voltage range when stop engine.

  • Page 16: Duty Cycle

    4-2. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. 100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC Continuous Welding SB-119 454-A OM-403 Page 12...

  • Page 17: Section 5 - Operating Auxiliary Equipment

    SECTION 5 – OPERATING AUXILIARY EQUIPMENT 5-1. Standard Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. 120 V 15 A AC Duplex Receptacle RC3 120 V 15 A AC Duplex...

  • Page 18: Optional Auxiliary Power Receptacles

    5-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. Combined output of all receptacles limited to 8 kVA/kW rating of the generator.

  • Page 19: Wiring Optional 240 Volt Plug

    5-3. Wiring Optional 240 Volt Plug The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired For 120/240 V, 3-Wire Load Current Available In Amperes When wired for 120 V loads, each duplex receptacle shares a load 240 V Each 120 V Duplex...

  • Page 20: Section 6 - Maintenance And Troubleshooting

    SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Y Stop engine before maintaining. See also Engine Manual and mainte- Recycle engine fluids. nance label. Service engine more often during severe conditions. 20 h Check And Check Fluid Clean Spark Wipe Up Levels.

  • Page 21: Maintenance Label

    50 hours Oil Filter ... . MILLER 065 251, Onan 122-0645 Oil Capacity ..1.5 qt (1.4 L) or 1.75 qt (1.6 L) with filter change Fuel Grade .

  • Page 22: Servicing Air Cleaner

    6-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Precleaner Wash precleaner with soap and wa- ter solution. Allow precleaner to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into precleaner.

  • Page 23: Changing Engine Oil, Oil Filter, And Fuel Filter

    6-4. Changing Engine Oil, Oil Filter, And Fuel Filter Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Y Close valve and valve cap before adding oil and run- ning engine.

  • Page 24: Adjusting Engine Speed

    6-5. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Turn Fine Adjust control to 10. ± 2200 100 rpm Idle Speed Adjustment Throttle Solenoid ±...

  • Page 25: Overload Protection

    6-6. Overload Protection Y Stop engine. Disconnect negative (–) battery cable. Fuse F1 (See Parts List) F1 protects the exciter excitation winding from overload. If F1 opens, there is no/low weld and auxiliary power output. Fuse F6 (See Parts List) F6 protects the engine wiring sys- tem from overload.

  • Page 26: Troubleshooting

    6-8. Troubleshooting A. Welding Trouble Remedy No weld output. Check control settings. Check weld connections. Check fuse F1 and replace if open (see Section 6-6). Check plug PLG6 connection. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
  • Page 27 C. Engine Trouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 6-6). Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG4 and plug PLG8 connection. Have Factory Authorized Service Agent check Engine Control switch S2. Engine will not start.

  • Page 28: Section 7 - Electrical Diagram

    SECTION 7 – ELECTRICAL DIAGRAM SB-180 688 Figure 7-1. Circuit Diagram For Welding Generator OM-403 Page 24...
  • Page 29 NOTES OM-403 Page 25...

  • Page 30: Section 8 - Parts List

    SECTION 8 – PARTS LIST ST-800 815-E Figure 8-1. Main Assembly OM-403 Page 26...
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....+159 907 COVER, top ........... . .
  • Page 32 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ....168 844 CONNECTOR, rect 4 pin/skt rcpt ........
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 40) ....184 754 SWITCH, polarity 5 position ........
  • Page 34 Item Part Description Quantity Figure 8-3. Generator (Fig 8-1 Item 20) ..013 367 LABEL, warning moving parts can cause serious injury ......

  • Page 35: Options And Accessories

    For 33 or 43 lb of coiled cable for transportation. and protect the finish of your tanks only. welder. Blue cover has MILLER Note: For best results do not weld when logo and name across side. FA–7.5 FLAME ARRESTOR...
  • Page 36 U.S. Federal Provides control circuitry to chains. Optional easy-to-install motor vehicle safety standards in effect operate spool gun from MILLER fender and light kit #043 301 on date of manufacture. and competitive engine-driven required for highway operation.
  • Page 37 Notes...
  • Page 38 Notes...
  • Page 39 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
  • Page 40 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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