Miller BOBCAT 225G PLUS Owner's manual

Miller

June1996

Form:

OM-175104A

Effective

With

Serial

No.

KG1

60360

OWNERS

MANUAL

(Kohier-Powered)

CCICV

ACIDC

Welding

Generator

For

SMAW,

FCAW,

GMAW,

GTAW

Welding

Mode

Weld

Output

Range

Rated

Welding

Output

Maximum

Open-

Circuit

Voltage

Auxiliary

Power

Rating

Fuel

Capacity

Engine

CC/AC

50225

A

~

225A,25V,

100%

Duty

Cycle

80

Single-Phase,

8

kVNkW,

70/35

A,

120/240

V

AC,

60Hz

8.5

gal

(32

L)

Tank

KohlerCHl8

Air-Cooled,

Two-Cylinder,

Four-Cycle,

18

HP

Gasoline

Engine

CC/DC

50

210

A

210

A,

25

V,

100%

Duty

Cycle

72

CV/DC

17-28V

200A,20V,

100%Duty

Cycle

33

Bobcat1M

225GP~

cover_om

4/95



Ref.

ST-801

188

'

1996

MILLER

Electric

Mfg.

co.

PRINTED

IN

USA

s-f

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

e

serial

number

preface

of

lCD

or

newer)

This

limited

warranty

supersedes

all

warranties

end

is

exclusive

with

no

other

gusrsntees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

theterms

and

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

ot this

limited

warranty

is

free

of

de

fecta

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPUED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

orcomponents

thatfail

due

to

such

defects

in

material

orworltnisnship.

MtLLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

Amencan

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

Intemahonal

distributor.

1.

5

Years

Parts

3

Years

Labor



Original

main

power

rectifiers

Inverters

(input

and

output

rectifiers

only)

2.

3

Years



Parts

and

Labor

*

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

*

Inverter

Power

Supplies



Infellitig



Robots

(1

year

labor)

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Enginea

are

warranted

aeparstely

by

the

engine

manufacturer.)



Air

Compressors

4.

1

YearPartaand

Labor



Motor

Driven

Guns



Process

Controllers



IHPS

Power

Sources



Water

Coolant

Systems

-

HF

Units



Grids



Spot

Welders



Load

Banks



SDX

Trsnafonners



Miller

Cyclomatic

Equipment



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

AFT,

ZIPCUT

&

PLAZCUT

Modela)

Tecumaeh

Engines



Deutz

Engines

(outside

North

Amenca)



Field

Optiona

(NOTE:

Field

optiona

are

covered

under

True

Blueﬁ

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

6.

90

Days



Parts

end

Labor



MIG

GunalflG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controla



Accessory

Kits



Replacement

Parta

MILLERS

True

Blueﬁ

umited

Warranty

shall

not

apply

to:

1.

Itema

fumiahed

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

ax

contact

tips,

cutting

nozzles,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MtLLER,

or

equip-

meet

that

has

been

improperiy

installed,

improperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALI1NDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUtPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the exclusive

remedies

sirall

be,

at

MILLERS

option:

(1)

repair;

or

(2)

replacement;

or;

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

coat

of

repair

or

replace

ment

at

an

authonzed

MILLER

service

station;

or

(4)

payment

of

orcredit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costa

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

TI-fE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT

INDIRECT,

SPECIAL,

INCIDENTALOR

CONSEDUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACt

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

ANDANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

DR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHTARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EGUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

ao

the

above

limrtahon

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

ataled

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

aet

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

WHO

DO

I

CONTACT?

For

help,



contact

your

diStribUtor

For

additional

information,

such

as

Technical

ManUa)S

(Service

And

Parts)

Engine

Manuals

Circuit

And

Wiring

Diagrams

Process

Handbooks

To

file

a

claim

for

loss

or

damage

during

shipment,



contact

the

delivering

carner

,

For

assistance

in

filing

or

settling

claims,



contact

your

distributor

and/or

equipment

manUfactUrers

Transportation

Department

~j~~j9)



jZT1

Miller

Electric

Mfg.

Co.



CALL:

4147354505

FAX:

800-637-2348

(in

USA),

or

414-735-4136

(outside

USA)

Users

Guides

Distributor

Directories



contact

your

distributor

o~



WRITE:

Miller

Electnc

Mfg.

Co.

P.O.

Box

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number



L

r...

1il



miller_wan

3/96

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

1

1-1.

Symbol

Usage

1

1-2.

Arc

Welding

Hazards

1

1-3.

Engine

Hazards

2

1-4.

Additional

Installation,

Operation,

And

Maintenance

Hazards

3

1-5.

Pnncipal

Safety

Standards

3

1-6.

EMF

Information

3

SECTION

2-

DEFINITIONS

4

2-1.

Symbol

Definitions

4

SECTION

3-INSTALLATION

5

3-1.

Installing

Welding

Generator

5

3-2.

Dimensions,

Weights,

And

Operating

Angles

5

3-3.

Fuel

Consumption

6

3-4.

Engine

Prestart

Checks

6

3-5.

Connecting

The

Battery

7

3-6.

Weld

Output

Terminals

And

Selecting

Cable

Sizes

7

SECTION

4-OPERATING

WELDING

GENERATOR

8

4-1.

Front

Panel

Controls

8

4-2.

Duty

Cycle

9

SECTION

5-OPERATING

AUXILIARY

EQUIPMENT

10

5-1.

Standard

Receptacles

10

5-2.

Optional

Auxiliary

Power

Receptacles

11

5-3.

Wiring

Optional

240

Volt

Plug

12

SECTION

6-

MAINTENANCE

AND

TROUBLESHOOTING

13

6-1.

Routine

Maintenance

13

6-2.

Maintenance

Label

14

6-3.

Servicing

Air

Cleaner

14

6-4.

Changing

Engine

Oil,

Oil

Filter,

And

Fuel

Filter

15

6-5.

Adjusting

Engine

Speed

16

6-6.

Overload

Protection

17

6-7.

Inspecting

And

Cleaning

Optional

Spark

Arrestor

17

6-8.

Troubleshooting

18

SECTION

7-

ELECTRICAL

DIAGRAM

20

SECTION

8-

PARTS

LIST

21

OM-175

104A-6/96

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

safety_romi

4/95

1-1.

Symbol

Usage

4A

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

A

Marks

a

special

safety

message.

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

~

Means

NOTE;

not

safety

related.

I

~

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

I

actions

to

avoid

the

hazards.

1-2.

Arc

Welding

Hazards

£~

WARNING

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

follow

the

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

1-5.

Read

and

follow

all

Safety

Standards.

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

During

operation,

keep

everybody,

especially

children

away.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

191

0.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

oower

cord

around

wire

is

orooerlv

connected

to

around

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workoiece

or

worktable

as near

the

weld

as

oractical.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing;

FLYING

~

SLAG

OR

SPARKS

can

injure

eyes.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

Arc

rays

from

the

welding

process

produce

intense

protect

your

face

and

eyes

when

welding

orwatching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

3.

Wear

approved

safety

glasses

with

side

shields.

processes

can

damage

heanng.

Chipping,

grinding,

and

welds

cooling

throw

oft

pieces

of

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

r

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

Welding

produces

fumes

and

gases.

Breathing

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

these

fumes

and

gases

can

be

hazardous

to

your

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

health.

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

OM-175

104

Page

1

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

oft

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

bums.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

____

a

WARNING

1

-3.

Engine

Hazards

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

pr

oduce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

explosion,

Engine

fuel

is

highly

flammable.

fire

or

2.

3.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

1.

Sto

p

eng

me

and

let

it

cool

off

before

checking

or

a

dding

fuel.

engine.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

4.

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

5.

6.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

engine

before

installing

or

connecting

unit,

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATrERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

Batteries

contain

acid

and

generate

explosive

3.

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

,

~

~/,.

~

STEAM

AND

PRESSURIZED

COOLANT

can

burn

face,

eyes,

skin.

It

is

best

to

check

coolant

level

when

eng

cold

to

avoid

scalding.

HOT

and

me

is

1.

2.

3.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

OM-175

104

Page

2

1-4.

Additional

Installation,

Operation,

And

Maintenance

Hazards

a

WARNING

MOVING

PARTS

can

cause

injury.

1.

Before

working

of

generator,

remove

spark

plugs

or

injectors

to

keep

engine

from

kicking

back

or

starting.

Block

flywheel

so

that

it

will

not

turn

while

working

on

generator

components.

FLYING

PIECES

OF

METAL

or

DIRT

can

injure

eyes.

1.

Wear

safety

glasses

with

side

shields

or

face

shield.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.

1.

Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.

1.

Pacemaker

wearers

keep

away.

2.

Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

HOT

PARTS

can

cause

severe

burns.

1.

Allow

cooling

period

before

maintaining.

2.

Wear

protective

gloves

and

clothing

when

working

on a

hot

engine.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.

1.

Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.

Use

equipment

of

adequate

capacity

to

lift

unit.

READ

INSTRUCTIONS.

1.

Use

only

genuine

MILLER

replacement

parts.

2.

Reinstall

injectors

and

bleed

air

from

fuel

system

according

to

engine

manual.

DO

NOT

LET

ENGINE

EXHAUST

SPARKS

CAUSE

FIRE.

1.

Use

approved

engine

exhaust

spark

arrestor

in

required

areas



see

applicable

codes.

J~

~{J~

~IJ

LOW

VOLTAGE

AND

FREQUENCY

CAN

DAMAGE

electrical

equipment

such

as

MOTORS.

1.

Turn

off

or

unplug

equipment

before

starting

or

stopping

engine.

-~--

I

OVERUSE

can

cause

OVERHEATED

EQUIPMENT.

1.

Allow

cooling

period.

2.

Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.

3.

Follow

rated

duty

cycle.

TILTING

OF

TRAILER

can

cause

injury.

1.

Use

tongue

jack

or

blocks

to

support

weight.

2.

Properly

install

welding

generator

onto

trailer

according

to

instructions

supplied

with

trailer.

1-5.

Principal

Safety

Standards

BATTERY

ACID

can

BURN

SKIN

AND

EYES.

1.

Donottip.

2.

Replace

damaged

battery.

3.

Flush

eyes

and

skin

immediately

with

water.

Safetyin

Welding

and

Cutting,

ANSI

Standard

Z49.i,from

American

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

Welding

Society,

550

N.W.

LeJeune

Ad,

Miami

FL

33126

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Highway,

Suite

501,

Arlington,

VA

22202.

Supenntendent

of

Documents,

U.S.

Government

Printing

Office,

Code

forSafetyin

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Washington,

D.C.

20402.

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Boulevard,

Rexdale,

Ontano,

Canada

M9W

1

R3.

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

American

Welding

Society

Standard

AWS

F4.

1,

from

American

Protection,

ANSI

Standard

Z87.1

from

American

National

Standards

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

Institute,

1430

Broadway,

New

York,

NY

i0018.

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1-6.

EMF

Information

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

Electric

And

Magnetic

Fields

procedures:

.

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

1.

Keep

cables

close

together

by

twisting

or

taping

them.

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Elect

tic

&

Magnetic

Fields



Background

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):...

there

is

now

a

very

large

volume

of

scientific

3.

Do

not

coil

or

drape

cables

around

the

body.

findings

based

on

experiments

at

the

cellular

level

and

from

studies

4.

Keep

welding

power

source

and

cables

as

far

away

as

with

animals

and

people

which

clearly

establish

that

low

frequency

practical.

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

possible.

interpret

the

evidence

in

a

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

About

Pacemakers.

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

The

above

procedures

are

also

recommended

for

pacemaker

strategies

to

minimize

or

avoid

potential

risks.

wearers.

Consult

your

doctor

for

complete

information.

OM-175

104

Page

3

2-1.

Symbol

Definitions

SECTION

2-

DEFINITIONS

OM-175

104

Page

4

SECTION

3-INSTALLATION

Height

Width

Depth

A

B

C

D

E

F

a

Dimensions

31

in

(787

mm)

6-3/4

in

(476

mm)

46

in

(1164

mm)

18

in

(457

mm)

6-1/2

in

(419

mm)

3/4

in

(19

mm)

3-1/8

in

(79

mm)

32-3/4

in

(832

mm)

45-1/2

in

(1156

mm)

13/32

in

(10mm)

Dia.

3-1.

Installing

Welding

Generator

3-2.

Dimensions,

Weights,

And

Operating

Angles

A

Do

not

exceed

operating

angles

while

running

or

engine

damage

will

occur.

A

Do

not

move

or

operate

unit

where

it

could

tip.

Weight

Net:

567

lb

(258

kg)

Ship:

608

lb

(276

kg)

OM-175

104

Page

5

Engine

End

ST-800

426

3-3.

Fuel

Consumption

.AUX

POWER

3750

RPM

DC

WELD



3750

RPM



 



~CW~LD

3750RPM

CV

WELD



3750RPM

-



~



~

¶

-

IDLE



2200

RPM



.



~



~



~



;;~

~

7.57

1.67

2.00

6.62

1.46

1.75

5.67

1.25

1.50

4.73

1.04

1.25

3.78

0.84

1.00

_______

______

2.84

0.63

0.75

1.89

0.42

0.50

0.95

0.21

0.25

I

10

0

25 50

75

100

125

150

175

200

225

250

275

WELD

AMPERES

AT

100%

DUTY

CYCLE

Q-

Cl)

I

0

1.0

2.0

3.0

4.0 5.0 6.0

7.0 8.0

9.0

10.0

11.0

POWER

KVA

AT

100%

DUTY

CYCLE

Ref.

SB.179

939

3-4.

Engine

Prestart

Checks

OM-175

104

Page

6

3-5.

Connecting

The

Battery

3-6.

Weld

Output

Terminals

And

Selecting

Cable

Sizes

~

.d.~,,

~

A

ARC

WELDING

can

cause

Electromagnetic

Interference.

~I

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.

Be

sure

this

welding

machine

is

installed

and

grounded

according

to

this

manual,

If

interference

still

occurs,

the

user

must

take

extra

measures

such

as

moving

the

welding

machine,

using

shielded

cables,

using

line

filters,

or

shielding

the

work

area.

Total

Cable

(Copper)

Length

In

Weld

Circuit

Not

Exceeding

!

~

lOOft30

Or

Less

150ft

200ft

250

ft

300ft

350ft

400ft

m,

(45

m)

(60

m)

(70

m)

(90

m)

(105

m)

(120

m)

w

1060%

60100%

Weld

Output

Terminals

elding

Duty

10

100%

Duty

Cycle

peres

Cycle

100

4

4 4

3 2

1

1/0

150

3

2

1

1/0

2/0

3/0

200

3

2

1

1/0

2/0

3/0

4/0

250

2

1

1/0

2/0

3/0

4/0

2-2/0

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

WORK

ELECTRODE

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

ST-800

396-A

Weld

cable

size

(AWG)

is

based

on

either

a

4

volts

or

less

drop

or

a

current

density

of

at

least

300

circular

mils

per

ampere.

5-0007-0

OM-175

104

Page

7

SECTION

4-

OPERATING

WELDING

GENERATOR

4-1.

Front

Panel

Controls

1

Engine

Control

Switch

Use

switch

to

start

engine,

select

speed,

and

stop

engine.

In

Run/Idle

position,

engine

runs

at

idle

speed

at

no

load,

and

weld/power

speed

under

load.

In

Run

position,

engine

runs

at

weld/power

speed.

OM-175

104

Page

8

Place

switch

in

Run

position

to

operate

most

GMAW

equipment.

2

Engine

Choke

Control

Use

control

to

change

engine

air-fuel

mix.

To

Start:

pull

out

choke

and

turn

Engine

Control

switch

to

Start

position.

Release

switch

and

slowly

push

choke

in

when

engine

starts.

Do

not

crank

engine

if

engine

is

still

turning.

Set

anti-icing

control

(see

Section

3-4).

To

Stop:

turn

Engine

Control

switch

to

Off

position.

3

Weld

Process

Selector

Switch

Use

switch

to

select

type

of

weld

output.

Use

a

positive

(+)

position

for

Direct

Current

Electrode

Positive

(DCEP)

and

a

negative

()

position

for

Direct

Current

Electrode

Negative

(DCEN).

Use

AC

position

for

alternating

current.

4

Coarse

Adjust

Switch

120V\,

D:1HI~l

IIIHEII

Use

switch

to

select

weld

amperage

range

when

Weld

Process

Selector

switch

is

in

Sticking

position,

or

voltage

range

when

switch

is

in

Wire

position.

~

For

best

arc

starts,

use

lowest

amperage

range

possible.

5

Fine

Adjust

Control

Use

control

to

select

weld

amperage

(Stick/

flg)

or

voltage

(Wire)

within

the

range

se

lected

by

the

Coarse

Adjust

switch.

Control

may

be

adjusted

while

welding.

Weld

output

would

be

110

A

DC

based

on

control

set

tings

shown

(50%

of

70

to

150

A).

6

Engine

Hour

Meter

I

00

NOT

SWITCH

UNDER

LOAD

COARS

A

WIRE

+

STiCK/Tb

-~DJUST

FINE

ADJUST

ENGINE

a

TotaiAllLoads8O

Watts

240V\.,

120V\.,

i

~

.In*canwT.yps~ThE

3

CESS

AC

POWER

Ref.

ST-i

78

079-A

4-2.

Duty

Cycle

0

Duty

cycle

is

the

percentage

of

10

minutes

that

unit

can

weld

at

rated

load

without

overheating.

Ac/cc

A

Exceeding

duty

cycle

can

damage

unit

and

void

warranty.

ocicc

DC/CV

250

225

_______

0

Ui

~

210

~200

Ui

150

10

15

20

25

30

40 50 60

70

60

SO

100

X

DUTY

CVCLE

100%

Duty

Cycle

at

225

Amperes

AC,

210

Amperes

CC/DC,

200

Amperes

CVIDC

Continuous

Welding

SB-119

454-A

OM-175

104

Page

9

SECTION

5-

OPERATING

AUXILIARY

EQUIPMENT

5-1.

Standard

Receptacles

_______________

~

Auxiliary

power

decreases

as

weld

current

increases.

Set

Fine

Adjust

control

Ri

at

10

for

full

auxiliary

power.

1

12OV15AAC

Receptacles

GFCI-2

And

GFCI-3

GFCI-2

and

GFCI-3

supply

60

Hz

single-phase

power

at

weld/power

speed.

Maximum

output

from

each

receptacle

is

2.4

kVAJkW

(CSA:

1.8

kVA/kW).

If

a

ground

fault

is

detected,

Reset

button

pops

out

and

the

circuit

opens

to

disconnect

the

faulty

equipment.

Check

for

faulty

tools,

cords,

etc.

connected

to

the

receptacle.

Press

reset

button

to

resume

operation.

~

At

least

once

a

month,

run

____________

engine

at

weld/power

speed

_____________

and

press

Test

button

to

verify

GFCI

is

working

properly.

2

240

V

50

A

AC

Receptacle

RC1

supplies

60

Hz

single-phase

power

at

weld/power

speed.

Maximum

output

is

8

kVA/kW.

3

Circuit

Breakers

CB1

And

CB2

CB1

and

CB2

protect

RC1

from

______________________________________________________________________________

overload.

If

CB1

or

CB2

opens,

RC1

and

one

of

the

120

volt

recep

tacles

does

not

work.

120

volts

may

still

be

present

at

RC1.

4

Circuit

Breakers

CB3

And

CB4

CB3

and

CB4

protect

GFCI-2

and

GFCI-3

from

overload.

If

CB3

or

CB4

opens,

the

receptacle

does

not

work.

fl~

If

a

circuit

breaker

continues

to

open,

contact

a

Factory

Authorized

Service

Agent.

Total

output

of

receptacles

limited

to

8

kVNkW.

Example:

If

20

A

is

drawn

from

GFCI-2

and

GFCI-3,

only

13

A

is

available

at

RC1:

2x(12OVx2OA)+(240Vx

13A)

=

7.9

kVA/kW

Ret.

ST-178

079-A

A

IOTAL

ALL

LOADS

00

240V~

4

8000

!M~T~S

o o

120V~

120V%,

~tC

POWER

OM-175

104

Page

10

5-2.

Optional

Auxiliary

Power

Receptacles

AC

POWER

A

If

unit

does

not

have

GFCI

receptacles,

use

GFC1-

protected

extension

cord.

~

Auxiliaiy

power

decreases

as

weld

current

increases.

Set

Fine

Adjust

control

Ri

at

10

forM!

auxiliasy

power.

Combined

output

of

all

receptacles

limited

to

8

kVA/kW

rating

of

the

generator.

120

Volt

Receptacle

Option

1

120

V

15

A

AC

Receptacles

RC2

And

RC3

RC2

and

RC3

supply

60Hz

single-

phase

power

at

weld/power

speed.

Maximum

output

from

RC2

or

RC3

is

2.4

kVA/kW

(CSA:

1.8

kVAIkW).

Circuit

breaker

protection

is

the

same

as

standard

receptacles.

South

African

And

Australian

Receptacle

Options

2

240

V

16

A

AC

South

African

Receptacles

RC1, RC2,

And

RC3

3

240

V

15

A

AC

Australian

Receptacles

RC1

RC2,

And

RC3

Receptacles

supply

60

Hz

single-

phase

power

at

weld/power

speed.

Maximum

output

from

each

recep

tacle

is

3.6

kVNkW.

4

Circuit

Breakers

CB1,

CB2,

CB3

CB1, CB2,

and

CB3

protect

Rd.

RC2,

and

RC3

from

overload.

If

a

circuit

breaker

opens,

the

recep

tacle

does

not

work.

Press

button

to

reset

breaker.

5

Circuit

Breaker

CB4

protects

all

the

receptacles

from

overload.

If

CB4

opens,

none

of

the

receptacles

work.

~

If

a

circuit

breaker

continues

to

open,

contact

a

Factory

Authorized

Service

Agent.

Ref.

ST-172

786-B

I

Ref.

ST-i

81

714

Totai

Au

Loads

8000

Watts

240V\.,

120V\.,

120V\.

__Ho

atov~

\

~

5

AC

POWER

3

OM-175

104

Page

11

5-3.

Wiring

Optional

240

Volt

Plug

Current

Available

In

Amperes

7

240

V

Receptacle*

35

30

25

20

15

Each

120

V

Duplex

Receptacle

V

x

A

=

Watts

The

plug

can

be

wired

for

a

240

V,

2-wire

load

or

a

120/240V,

3-wire

load.

See

circuit

diagram.

1

Plug

Wired

For

120/240

V,

3-Wire

Load

0

5

10

15

20

One

240

V

load

or

two

120

V

loads.

When

wired

for

120

V

loads,

each

duplex

receptacle

shares

a

load

with

one

half

of

240

V

receptacle.

2

Plug

Wired

For

240

V,

2-Wire

Load

5

I-

3

4

5

6

7

Neutral

(Silver)

Terminal

Load

1

(Brass)Terminal

Load

2

(Brass)

Terminal

Ground

(Green)

Terminal

Amperes

Available

Using

120/240

V

Plug

6

5

Tools

Needed:

===~_

ST-120

813-0

OM-175

104

Page

12

SECTION

6-

MAINTENANCE

AND

TROUBLESHOOTING

6-1.

Routine

Maintenance

ﬁ

20h

Recycle

engine

fluids.

A

Stop

engine

before

maintaining.

See

also

Engine

Manual

and

mainte

nance

label.

Se,vice

engine

more

often

during

severe

conditions.

50h

lOOh

ﬁ

200h

Repair

Or

Replace

Cracked

Cables.

500h

4

l000h

OM-175

104

Page

13

6-2.

Maintenance

Label

A

Stop

engine.

A

Do

not

run

engine

without

air

cleaner

or

with

dirty

element.

1

Precleaner

Wash

precleaner

with

soap

and

water

solution.

Allow

precleaner

to

air

dry

completely.

Spread

1

tablespoon

SAE

30

oil

evenly

into

precleaner.

Squeeze

out

excess

oil.

2

Element

Replace

element

if

dirty

or

oily.

KOHLER

CH18

GAS

ENGINE

r-i

l2VoltBattery

BClGroup58



+

J

Cranking

Performance

at

0F

(-18C)

...

.

430

Amps

mm.

6-3.

Servicing

Air

Cleaner

2

L__~

-,

-4

aircleaner3

4/96



ST-i

56

852/

S-0759

OM-175

104

Page

14

6-4.

Changing

Engine

Oil,

Oil

Filter,

And

Fuel

Filter

Tools

Needed:

~

L~ji

A

Stop

engine

and

let

cool.

1

Oil

Drain

Valve

2

1/2lDxl2inHose

3

Oil

Filter

4

Oil

Fill

Cap

5

Oil

Dipstick

Change

engine

oil

and

filter

ac

cording

to

engine

owners

manual.

A

Close

valve

and

valve

cap

before

adding

oil

and

run

ning

engine.

Fill

crankcase

with

new

oil

to

full

mark

on

dipstick

(see

Section

6.2).

6

Fuel

Filter

7

FuelLine

Replace

line

if

cracked

or

worn.

Install

new

filter.

Wipe

up

any

spilled

fuel.

Start

engine,

and

check

for

fuel

leaks.

Ref.

ST-801

188

/

Ref.

ST-801

221

/

Ref.

ST-I

78079-A

/

ST-800

395

/

S-0842

A

Stop

engine,

tighten

connections

as

necessary,

and

wipe

up

fuel.

OM-175

104

Page

15

Tools

Needed:

~:=~z

1/4,3/8in

6-5.

Adjusting

Engine

Speed

2200–50rpm

3700–50rpm

to

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.

Idle

Speed

Adjustment

Move

Engine

Control switch

Run/Idle

position.

1

Throttle

Solenoid

2

Mounting

Screws

3

Idle

Speed

Screw

Loosen

mounting

screws.

Adjust

solenoid

position

so

engine

runs

at

idle

speed.

If

necessary,

back

out

idle

speed

screw

so

solenoid

can

be

moved

to

correct

position.

Tighten

mounting

screws.

Be

sure

solenoid

linkage

works

smoothly.

Turn

idle

speed

screw

for

fine

adjustments.

Weld/Power

Speed

Adjustment

Move

Engine

Control

switch

to

Run

position.

4

Weld/Power

Speed

Adjustment

Nut

5

Lock

Nut

Loosen

lock

nut.

Turn

adjustment

nut

until

engine

runs

at

weld/power

speed.

Tighten

lock

nut.

A

Stop

engine.

ST-801

209

/

Ref.

ST-801

188

OM-175

104

Page

16

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