Engine Driven Welding Generator Bobcat 225 NT

1 Bobcat 225 NTBobcat 225 NTProcessesDescriptionOM-405 February 1997 Effective withSerial NumberKH329624 Non-Critical TIG (GTAW)WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorMiller Electric manufactures a full lineof welders and Welding related information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor call you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou don t have time to do it any other s why when Neils Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldn t afford anything less. Miller productshad to be more than the best they could be.

2 They had tobe the best you could , the people that build and sell Miller products continue thetradition. They re just as committed to providing equipment and servicethat meets the high standards of quality and value established in Owner s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They willhelp you protect yourself against potential hazards on the worksite. We vemade installation and operation quick and Miller you can count on years of reliableservice with proper maintenance. And if forsome reason the unit needs repair, there s aTroubleshooting section that will help youfigure out what the problem is. The parts listwill then help you to decide which exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also is the firstwelding equipmentmanufacturer in to be regis-tered to the ISO 9001 Quality System as hard as youdo every power sourcefrom Miller is backedby the most hassle-freewarranty in the Miller to YouBobcat 225 NTBobcat 225 NTNon-Critical TIG (GTAW)WeldingStick (SMAW) WeldingMIG (GMAW) WeldingDescriptionProcessesFeatures New full case, rugged housing.

3 Protects engineand internal components from potentialdamage. 60% more sheet metal built into thisdurable design compared to the previousmodel. Enlarged, 10 gallon fuel tank and new fuelgauge. 18% more capacity than the previousBobcat series. Larger capacity means morerunning time before refueling. Standard fuelgauge is accurate and easy to read . Top fuel/oil fill. Fuel fill located on top of unitallows for easier, more convenient refueling,plus an overflow cavity directs any spillageaway from the unit. Oil dipstick and fill cap areeasily accessed on top of unit. Fastex oil draindoes not require tools. New smart fuel tank design. Patent-pendingdesign of the reservoir minimizes the chance offuel backflow. Rotatable exhaust pipe. Adjust exhaust pipe inany direction 360 degree rotation new muffler design provides quieter,improved sound quality.

4 8000 watts of AC auxiliary power. Dualpurpose welder and power Generator providesneeded power at job sites. Auxiliary powerreceptacle supplies up to 35 amps of 120 or240 volts ac to a single load. (Optional GFCI kits available.)1. Safety Precautions read Before Using1. 2. Definitions9.. 3. Specifications9.. 4. Installation13.. 5. Operating Welding Generator16.. 6. Operating Auxiliary Equipment17.. 7. Maintenance (Onan-Powered Units)20.. 8. Maintenance (Kohler-Powered Units)26.. 9. Troubleshooting31.. 10. Electrical Diagrams33.. 11. Auxiliary Power Guidelines35.. 12. Stick Welding (SMAW) Guidelines42.. 13. MIG Welding (GMAW) Guidelines50.. 14. Parts List60.. Options and AccessoriesWarrantySectionPageTable of ContentsMiller offers a Technical Manualwhich provides more detailedservice and parts information foryour unit. To obtain a TechnicalManual, contact your localdistributor.

5 Your distributor can alsosupply you with Welding ProcessManuals such as SMAW, GTAW,GMAW, and your localMiller distributor givesyou ..ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 fast answers to thetough Welding questions?Contact your expertise of thedistributor and Miller isthere to help you, everystep of the way. The following terms are used interchangeably inthis manual: Stick = SMAW, TIG = GTAW,MIG = GMAW or WireThe Bobcat 225 NT begins a new tradition inportable Engine - Driven Welding generators. Thenew tradition (NT) design includes all the provencapabilities of the famous Bobcat 225 Pluscombined with innovative features that meet themulti-purpose needs of contractors at the job sites. Standard Engine hour meter. Helps maintainscheduled preventative maintenance.

6 Two-pole alternator design. Producesdependable single-phase Welding arc. CV setting with fine adjustment. Premiumperformance control when MIG (60/10) andFlux Cored wire Welding . Use CV-DC weldoutput for MIG and flux cored wires. Three overlapping amperage ranges in CCmode, with fine adjustment. Provides precisearc control when Stick Welding . 225 amps of AC weld output and versatileAC/DC output for Stick. Multi-processcapability handles a variety of Welding output perfect for most common Stickelectrode types and sizes. Process selector switch. Quick, simplechange from one weld process to another, ACto DC straight or DC reverse polarity. Two Engine choices. Customize the newBobcat NT with your choice of two gasolineengines: Onan 16 HP or Kohler 18 HP. Miller s True Blue Warranty. New for 1997!We ve extended our warranty on weldinggenerators to 3 years parts and is warranted separately by the Engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive Safety Precautions read Before UsageOM-405 - 12/96, safety_rom 12/96 Means Warning!

7 Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means Note ; not safety group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS symbols and related instructions below for necessary actionsto avoid the Welding Hazards The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section read and follow allSafety Standards. Only qualified persons should install, operate, maintain, andrepair this unit. During operation, keep everybody, especially children, SHOCK can live electrical parts can cause fatal shocksor severe burns.

8 The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automatic wire Welding , thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground. Disconnect input power or stop Engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR (see Safety Standards). Properly install and ground this equipment according to itsOwner s Manual and national, state, and local codes.

9 Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet. When making input connections, attach proper grounding conduc-tor first double-check connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directlywith a separate cable do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine. Use only well-maintained equipment.

10 Repair or replace damagedparts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as DC VOLTAGE exists after removal ofinput power on inverters. Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any rays from the Welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Noise from someprocesses can damage RAYS can burn eyes and skin. Wear a Welding helmet fitted with a proper shade of filter to protectyour face and eyes when Welding or watching (see ANSI listed in Safety Standards).