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Miller KG160360, BOBCAT 225G PLUS Owner's manual

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  • What welding processes does the Miller BOBCAT 225G PLUS support?
    What is the maximum welding output of the Miller BOBCAT 225G PLUS?
    What is the maximum open-circuit voltage of the Miller BOBCAT 225G PLUS?
    What is the duty cycle of the Miller BOBCAT 225G PLUS?
    What is the auxiliary power rating of the Miller BOBCAT 225G PLUS?
    What type of engine does the Miller BOBCAT 225G PLUS have?
    What is the fuel capacity of the Miller BOBCAT 225G PLUS?
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
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
previous
MILLER
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
related
instructions
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
related
instructions
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
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
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
I
10
0
25 50
75
100
125
150
175
200
225
250
275
WELD
AMPERES
AT
100%
DUTY
CYCLE
Q-
Cl)
I
I
I
I
I
I
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
Duty
10
100%
Duty
Cycle
peres
Cycle
Cycle
100
4
4 4
3 2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
WORK
ELECTRODE
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
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
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
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
6-4.
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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