Miller Electric 225 Owner's Manual

Bobcat 225 NTProcessesDescriptionNon-Critical TIG (GTAW)WeldingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW) WeldingEngine Driven Welding G

OM-405 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utili

OM-405 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection

OM-405 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-405 Page 9SECTION 3 − DEFINITIONS3-1. Symbol DefinitionsStop EngineFast(Run, Weld/Power)Fast/Slow(Run/Idle)Slow (Idle)Start EngineRead Operator’sMa

OM-405 Page 104-2. Dimensions, Weights, and Operating AnglesDimensionsAHeight 33-1/2 in (851 mm)BCWidth 18-3/4 in (476 mm)C Do not exceed tilt angles

OM-405 Page 114-4. Fuel Consumption179 939Continuous Welding4-5. Duty Cycle119 454-ADuty cycle is the percentage of 10minutes that unit can weld at ra

OM-405 Page 124-6. Volt-Ampere Curves166 024-A / 166 025-A / 166 026-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output ca

OM-405 Page 13SECTION 5 − INSTALLATIONinstall2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Do not weld on base. Weldingon base can cause fuel tank

OM-405 Page 145-2. Engine Prestart ChecksRef. 801 188-E / Ref. 801 221-ACheck all fluids daily. Engine mustbe cold and on a level surface. Unitis ship

OM-405 Page 155-3. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber G

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-405 Page 165-4. Connecting the BatteryRef. 800 394-C / Ref. 183 175-A / Ref. S-0756-D3/8, 1/2 inTools Needed:+− Connect negative (−)cable last.5-5

OM-405 Page 175-6. Connecting to Weld Output Terminals800 396-B / Ref. 208 296-C1 Work Weld Output Terminal2 Electrode Weld OutputTerminalConnect work

OM-405 Page 18SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Front Panel ControlsRef. 208 296-C1 Engine Control SwitchUse switch to start engine, sel

OM-405 Page 196-2. Typical Stick Welding Connections And Control SettingsRef. 800 395 / 208 296-C / 087 985-A / Ref. S-0653 Stop engine. This sectio

OM-405 Page 206-3. Typical MIG Welding Connections And SettingsA. Solid Wire Applications802 766 / 208 296-C Stop engine. This section provides gene

OM-405 Page 21B. Self-Shielded Flux Core Wire Applications802 766 / 208 296-C Stop engine. This section provides generalguidelines and may not suit

OM-405 Page 226-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun802 750 / 208 296-C This section provides general guide-lines

OM-405 Page 23SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Standard ReceptaclesRef. 208 296-C If unit does not have GFCI re-ceptacles, use GFCI-prot

OM-405 Page 2456237-2. GFCI/CSA Receptacle Option If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord.1 120/240 V 50 A AC Rece

OM-405 Page 257-3. Wiring Optional 240 Volt Plug120 813-DThe plug can be wired for a 240 V,2-wire load or a 120/240V, 3-wireload. See circuit diagram.

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-405 Page 26SECTION 8 − MAINTENANCE8-1. Routine MaintenanceFollow storage procedure in engine manual if the unit will not be used for an extended pe

OM-405 Page 278-2. Maintenance Label

OM-405 Page 288-3. Servicing Air Cleaner aircleaner4 1/97 − 802 822 / Ref. 200 017 / S-0759 Stop engine. Do not run engine without aircleaner or wit

OM-405 Page 298-4. Changing Engine Oil, Oil Filter, and Fuel FilterRef. 801 188-E / Ref. 183 175-A / 800 395 / S-0842 Stop engine and let cool.1 Oil

OM-405 Page 308-5. Adjusting Engine SpeedRef. 801 188-E / 801 209-AAfter tuning engine, check enginespeeds with a tachometer (seetable). If necessary,

OM-405 Page 318-6. Overload Protection801 226-G / Ref. 801 221-A / Ref. 183 175−A Stop engine. Disconnectnegative (−) battery cable.1 Fuse F1 (See Pa

OM-405 Page 32SECTION 9 − TROUBLESHOOTING9-1. Welding TroubleshootingTrouble RemedyNo weld output. Check control settings (see Section 6).Check weld c

OM-405 Page 339-3. Engine TroubleshootingTrouble RemedyEngine will not crank. Check fuse F6, and replace if open (see Section 8-6).Check battery volta

OM-405 Page 34SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator

OM-405 Page 35216 624-B

TABLE OF CONTENTSSECTION 13 − MIG WELDING (GMAW) GUIDELINES 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-405 Page 36SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generator

OM-405 Page 3711-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-405 Page 3811-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-405 Page 3911-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-405 Page 4011-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-405 Page 4111-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-405 Page 4211-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-405 Page 43SECTION 12 − STICK WELDING (SMAW) GUIDELINES12-1. Stick Welding Procedurestick 12/96 − ST-151 593 Weld current starts whenelectrode tou

OM-405 Page 4412-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43/

OM-405 Page 4512-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode AngleE

OM-405 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these

OM-405 Page 4612-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness of

OM-405 Page 4712-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posit

OM-405 Page 4812-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3 i

OM-405 Page 4912-16. Troubleshooting − Incomplete FusionIncomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding we

OM-405 Page 5012-19. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metal resultingin holes where no metal re

OM-405 Page 51SECTION 13 − MIG WELDING (GMAW) GUIDELINES13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder Weld current can da

OM-405 Page 5213-3. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, shie

OM-405 Page 5313-4. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigg

OM-405 Page 5413-5. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout), tr

OM-405 Page 5513-6. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide g

OM-405 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyin

OM-405 Page 5613-9. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead.

OM-405 Page 5713-12. Troubleshooting − Lack Of PenetrationLack Of Penetration − shallowfusion between weld metal andbase metal.Lack of Penetration Goo

OM-405 Page 5813-15. Troubleshooting − Waviness Of BeadWaviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal

OM-405 Page 5913-17. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures

OM-405 Page 60SECTION 14 − PARTS LISTST-801 742-M Hardware is common andnot available unless listed.47Fig.14-3 − 403937413845424344292730353631323349

OM-405 Page 61DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main AssemblyQuantity1 181 881 GROMMET, neck filler 1. . . . . . . . . . . . . . . . .

OM-405 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main Assembly (Continued)Quantity37 SR1 192 682 RECTIFIER, si 1 ph 240A 400PIV 1. . . .

OM-405 Page 63DescriptionPartNo.ItemNo.Figure 14-2. Generator (Figure 14-1 Item 19)Quantity1 +216 625 GENERATOR ASSEMBLY, front (consisting of) 1. . .

OM-405 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 40) (Continued)Quantity1 S1 184 754 SWITCH, p

OM-405 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at ov

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 3/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-405 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and se

OM-405 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez