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Miller BOBCAT 225G PLUS User Manual

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

General IconGeneral
BrandMiller
ModelBOBCAT 225G PLUS
CategoryWelding System
LanguageEnglish

Summary

Introduction and Company Information

From Miller to You

A welcoming message from the manufacturer detailing company history and commitment to quality.

True Blue Warranty Highlight

Overview of Miller's comprehensive warranty program.

Safety Precautions

Symbol Usage and Hazard Identification

Explains safety symbols and the meaning of various hazard warnings in the manual.

Arc Welding Hazards

Details risks like electric shock, noise, and fumes during welding.

Engine Hazards

Covers risks related to fuel, exhaust gases, moving parts, and battery safety.

Installation, Operation, and Maintenance Hazards

Additional risks during setup, use, and upkeep, including electrical and mechanical dangers.

Principal Safety Standards

Lists key safety standards and codes relevant to welding operations.

EMF Information

Discusses the effects of low frequency electric and magnetic fields on biological systems.

Definitions

Symbol Definitions

Explains the meaning of various symbols and icons used throughout the manual.

Installation

Installing the Welding Generator

Guidance on proper placement, airflow clearance, and grounding procedures.

Dimensions, Weights, and Operating Angles

Provides physical specifications and limits for operating angles to prevent damage.

Fuel Consumption

Details fuel usage rates for different operating modes and loads.

Engine Prestart Checks

Essential checks, including fluid levels, before starting the engine.

Connecting the Battery

Step-by-step instructions for correctly connecting the battery terminals.

Weld Output Terminals and Cable Sizing

Guide to connecting weld output terminals and selecting appropriate cable sizes.

Operating the Welding Generator

Front Panel Controls Overview

Explains the function of each control knob, switch, and meter on the front panel.

Understanding Duty Cycle

Information on unit's operational duty cycle limits to prevent overheating.

Auxiliary Equipment Operation

Standard Receptacles

Details on built-in 120V and 240V power outlets and their circuit breakers.

Optional Auxiliary Power Receptacles

Information on available optional power outlet configurations.

Wiring the 240 Volt Plug

Instructions for wiring an optional 240V plug for different load configurations.

Maintenance and Troubleshooting

Routine Maintenance Schedule

Periodic maintenance tasks and recommended intervals for the equipment.

Maintenance Label Information

Explanation of the details provided on the engine maintenance label.

Servicing the Air Cleaner

Step-by-step guide for cleaning and maintaining the air cleaner element.

Changing Engine Oil and Filters

Procedure for changing engine oil, oil filter, and fuel filter.

Adjusting Engine Speed

How to set idle speed and weld/power speed using adjustment controls.

Overload Protection and Fuses

Details on fuses F1 and F6 that protect against electrical overloads.

Spark Arrestor Servicing

Instructions for cleaning and inspecting the spark arrestor screen.

Troubleshooting Guide

Solutions for common welding, auxiliary power, and engine operational issues.

Electrical Diagram

Parts List

Main Assembly Parts

List of parts for the main assembly with diagrams and part numbers.

Front Panel Components

Parts breakdown for the front panel, including switches, meters, and receptacles.

Generator Components

List of parts for the generator assembly, including rotor, stator, and brushes.

Options and Accessories

Warranty Policy

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