Miller Bobcat 225 Engine-Driven Welder Owners Manual

Miller Bobcat 225 Engine-Driven Welder

Arc Welding Hazards

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.

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.
• Wear dry, hole-free insulating gloves and body protection.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.
• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use the remote output control if present on the unit.
• Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such
  as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in the order presented:
  • a semiautomatic DC constant voltage (wire) welder,
  • a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, the use of a DC, constant voltage wire welder is recommended. And, do not work alone!
• Disconnect the input power or stop the engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).
• Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.
• Always verify the supply ground — check and be sure that the input power cord ground wire is properly connected to the ground terminal in the disconnect box or that the cord plug is connected to a properly grounded receptacle outlet.
• When making input connections, attach proper grounding conductor first − double-check connections.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect the input power cord for damage or bare wiring —replace the 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 directly with a separate cable.
• Do not touch the electrode if you are in contact with the work, ground, or another electrode from a different machine.
• Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
• Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.
• 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 workpiece or worktable as near the weld as practical.
• Insulate the work clamp when not connected to the workpiece to prevent contact with any metal object.
• Do not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stopping the engine.

• Stop the engine on the inverter and discharge input capacitors according to instructions in the Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

• Do not touch hot parts bare-handed.
• Allow a cooling period before working on equipment.
• To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure the eyes.

• Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
• Wear approved safety glasses with side shields even under your welding helmet.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

• Keep your head out of the fumes. Do not breathe the fumes
• If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
• If ventilation is poor, wear an approved air-supplied respirator.
• Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.
• Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
• Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
• Do not weld on coated metals, such as galvanized, lead, or cadmium-plated steel, unless the coating is removed from the weld area, the area is well-ventilated, and while wearing an air-supplied
  respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

• Shut off shielding gas supply when not in use.
• Always ventilate confined spaces or use an approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in
  Safety Standards).
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc.
• Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

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 off from the welding arc. The flying sparks, hot workpieces, and hot equipment can cause fires and burns. Accidental contact of electrodes with metal objects can cause sparks, explosions, overheating, or fire. Check and be sure the area is safe before doing any welding.

• Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
• Do not weld where flying sparks can strike flammable material.
• Protect yourself and others from flying sparks and hot metal.
• Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
• Watch for fire, and keep a fire extinguisher nearby.
• Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
• 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).
• Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
• Connect the work cable to the work as close to the welding area as practical to prevent the welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.
• Do not use a welder to thaw frozen pipes.
• Remove the stick electrode from the holder or cut off the welding wire at the contact tip when not in use.
• Wear oil-free protective garments such as leather gloves, heavy shirts, cuffless trousers, high shoes, and a cap.
• Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
• After completion of work, inspect the area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them.
• Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

• Wear approved ear protection if the noise level is high.

MAGNETIC FIELDS can affect Implanted Medical Devices.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.
• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

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, so be sure to treat them carefully.

• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
• Install cylinders in an upright position by securing them to a stationary support or cylinder rack to prevent falling or tipping.
• Keep cylinders away from any welding or other electrical circuits.
• Never drape a welding torch over a gas cylinder.
• Never allow a welding electrode to touch any cylinder.
• Never weld on a pressurized cylinder — an explosion will result.
• Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
• Turn your face away from the valve outlet when opening the cylinder valve.
• Keep a protective cap in place over the valve except when the cylinder is in use or connected for use.
• Use the right equipment, correct procedures, and a sufficient number of persons to lift and move cylinders.
• Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

Engine Hazards

BATTERY EXPLOSION can BLIND.

• Always wear a face shield, rubber gloves, and protective clothing when working on a battery.
• Stop the engine before disconnecting or connecting battery cables or servicing the battery.
• Do not allow tools to cause sparks when working on a battery.
• Do not use a welder to charge batteries or jump-start vehicles.
• Observe correct polarity (+ and −) on batteries.
• Disconnect the negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

• Stop the engine and let it cool off before checking or adding fuel.
• Do not add fuel while smoking or if the unit is near any sparks or open flames.
• Do not overfill the tank — allow room for fuel to expand.
• Do not spill fuel. If fuel is spilled, clean up before starting the engine.
• Dispose of rags in a fireproof container.
• Always keep the nozzle in contact with the tank when fueling.

MOVING PARTS can cause injury.

• Keep away from fans, belts, and rotors.
• Keep all doors, panels, covers, and guards closed and securely in place.
• Stop the engine before installing or connecting the unit.
• Have only qualified people remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
• To prevent accidental starting during servicing, disconnect the negative (−) battery cable from the battery.
• Keep hands, hair, loose clothing, and tools away from moving parts.
• Reinstall doors, panels, covers, or guards when servicing is finished and before starting the engine.
• Before working on the generator, remove spark plugs or injectors to keep the engine from kicking back or starting.
• Block the flywheel so that it will not turn while working on generator components.

HOT PARTS can cause severe burns.

• Do not touch hot parts bare-handed.
• Allow a cooling period before working on equipment.
• To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

BREATHING COMPRESSED AIR can cause serious injury or death.

• Do not use compressed air for breathing.
• Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

• Wear approved safety goggles.
• Do not direct the air stream toward self or others.

STEAM AND HOT COOLANT can burn.

• If possible, check the coolant level when the engine is cold to avoid scalding.
• Always check the coolant level at the overflow tank, if present on the unit, instead of the radiator (unless told otherwise in the maintenance section or engine manual).
• If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
• Wear safety glasses and gloves and put a rag over the radiator cap.
• Turn the cap slightly and let pressure escape slowly before completely removing the cap.

Using a generator indoors CAN KILL YOU IN MINUTES.

• Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
• NEVER use inside a home or garage, EVEN IF doors and windows are open.
• Only use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and EYES.

• Do not tip the battery.
• Replace the damaged battery.
• Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

• Do not locate the unit on, over, or near combustible surfaces or flammables.
• Keep exhaust and exhaust pipes away from flammables.

EXHAUST SPARKS can cause a fire.

• Do not let engine exhaust sparks cause fire.
• Use approved engine exhaust spark arrestor in required areas — see applicable codes.

Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

• Do not use compressed air for breathing.
• Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

• Wear approved safety goggles.
• Do not direct the air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

• Release air pressure from tools and systems before servicing, adding or changing attachments,
  or opening compressor oil drain or oil fill cap.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

• Do not cut or gouge near flammables.
• Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

• Do not touch the hot compressor or air system parts.
• Let the system cool down before touching or servicing.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

• Do not install or place the unit on, over, or near combustible surfaces.
• Do not install the unit near flammables.
• Do not overload building wiring − be sure the power supply system is properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

• Use a lifting eye to lift the unit and properly install accessories only, NOT gas cylinders. Do not
  exceed maximum lift eye weight rating (see Specifications)
• Lift and support the unit only with proper equipment and correct procedures.
• If using lift forks to move the unit, be sure the forks are long enough to extend beyond the opposite side of the unit.

OVERHEATING can damage motors.

• Turn off or unplug equipment before starting or stopping the engine.
• Do not let low voltage and frequency caused by low engine speed damage electric motors.
• Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

FLYING SPARKS can cause injury.

• Wear a face shield to protect your eyes and face.
• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
• Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.

WELDING WIRE can cause injury.

• Do not press the gun trigger until instructed to do so.
• Do not point a gun toward any part of the body, other people, or any metal when threading welding wire.

OVERUSE can cause OVERHEATING.

• Allow cooling period; follow rated duty cycle.
• Reduce current or reduce duty cycle before starting to weld again.
• Do not block or filter airflow to the unit.

STATIC (ESD) can damage PC boards.

• Put on a grounded wrist strap BEFORE handling boards or parts.
• Use proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

• Use tongue jack or blocks to support weight.
• Properly install welding generator onto trailer according to instructions supplied with trailer.

READ INSTRUCTIONS.

• Read the Owner’s Manual before using or servicing the unit.
• Use only genuine replacement parts from the manufacturer.
• Perform engine and air compressor maintenance and service according to this manual and the engine/air compressor (if applicable) manuals.

H.F. RADIATION can cause interference.

• High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
• Have only qualified persons familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep spark gaps at the correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

• Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors,
  computers, and computer-driven equipment such as robots.
• Be sure all equipment in the welding area is electromagnetically compatible.
• 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.

California Proposition 65 Warnings

WARNING:

• Welding or cutting equipment produces fumes or gases that contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
• Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

For Gasoline Engines:

• Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:

• Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).

EMF Information

Considerations About Welding And The Effects Of Low-Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when
welding or cutting. To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from the operator as practical.
5. Connect the work clamp to the workpiece as close to the weld as possible.

About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

Symbol Definitions

Dimensions, Weights, and Operating Angles

Dimensions For Units With Optional Running Gear

Fuel Consumption (Subaru/Robin-Powered Units)

Fuel Consumption (Kohler-Powered Units)

Installing Exhaust Pipe

Selecting Weld Cable Sizes*

Servicing Air Cleaner (Subaru/Robin-Powered Units)

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Miller Bobcat 225 Engine-Driven Welder-FAQs