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January 1997 Form: OM-175 104B
Effective With Serial No. KG191348
OWNER’S
MANUAL
Bobcat 225G
(Kohler-Powered)
CC/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW Welding
Weld Rated Maximum
Welding Auxiliary Power
Output Welding Open-Circu Fuel Capacity Engine
Mode Rating
Range Output it Voltage
225 A, 25 V,
100% Duty
CC/AC 50 – 225 A 80
Cycle
Kohler CH18 Kohler CH18
210 A, 25 V, Single-Phase,
Air-Cooled, Two-Cylinder,
100% Duty
CC/DC 50 – 210 A 72 8 kVA/kW, 70/35 A,
8.5 gal (32 L)
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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 . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_rom1 4/95 1-1. Symbol Usage Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. 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 actions to avoid the hazards. 1-2. Arc Welding H
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4. Never drape a welding torch over a gas cylinder. CYLINDERS can explode if damaged. 5. Never allow a welding electrode to touch any cylinder. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. 6. Never weld on a pressurized cylinder – explosion will result. Since gas cylinders are normally part of the welding 7. Use only correct shielding gas cylinders, regulators, hoses, and process, be sure to treat them carefully. fittings designed for the specific
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1-4. Additional Installation, Operation, And Maintenance Hazards WARNING MOVING PARTS can cause injury. READ INSTRUCTIONS. 1. Before working of generator, remove spark plugs 1. Use only genuine MILLER replacement parts. or injectors to keep engine from kicking back or 2. Reinstall injectors and bleed air from fuel system starting. according to engine manual. 2. Block flywheel so that it will not turn while working on generator components. DO NOT LET ENGINE EXHAUST SPARKS FLYING PIECES OF METAL o
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SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts A V Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch Engine Choke Work Connection Clearance while welding Alternating Current Positive Negative Output (AC) Gas Metal Arc Shielded Metal Arc Welding Arc Gas Tungsten Arc Welding (GMAW), Welding (SMAW), (Electrode) Welding (TIG) Wire Stick Protective Earth Hours Seconds
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SECTION 3 – INSTALLATION 3-1. Installing Welding Generator Movement Airflow Clearance Location 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding 1 Generator Base 3 2 Metal Vehicle Frame 1 GND/PE 4 3 Equipment Grounding Terminal 4 Grounding Cable OR Use #10 AWG or larger insulated copper wire. Electrically bond generator frame to vehicle frame by metal-to-metal 2 contact. 2 install1* 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 3-2. D
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3-3. Fuel Consumption 2.0 7.57 1.67 AUX POWER 1.8 6.62 1.46 3750 RPM DC WELD 3750 RPM 1.5 5.67 1.25 AC WELD 1.04 1.3 4.73 3750 RPM 1.0 3.78 0.84 CV WELD 3750 RPM 0.8 2.84 0.63 0.5 0.42 1.89 IDLE 0.21 0.3 0.95 2200 RPM 0.0 0 25 50 75 100 125 150 175 200 225 250 275 WELD AMPERES AT 100% DUTY CYCLE 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 Check all fluids daily. Engine must be cold and on a level surface. Unit is shippe
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3-5. Connecting The Battery Connect (–) cable last. – + Tools Needed: 3/8, 1/2 in Ref. ST-800 394-B / Ref. ST-178 079-A / Ref. S-0756-D 3-6. Weld Output Terminals And Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference. 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
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SECTION 4 – OPERATING WELDING GENERATOR 4-1. Front Panel Controls 4 5 1 6 2 3 Ref. ST-178 079-A 1 Engine Control Switch gine starts. Do not crank engine if engine is Use switch to select weld amperage range still turning. Set anti-icing control (see Sec- when Weld Process Selector switch is in Use switch to start engine, select speed, tion 3-4). Stick/Tig position, or voltage range when and stop engine. In Run/Idle position, en- switch is in Wire position. gine runs at idle speed at no load, and
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4-2. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void war- ranty. 100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC Continuous Welding SB-119 454-A OM-175 104 Page 9
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SECTION 5 – OPERATING AUXILIARY EQUIPMENT 5-1. Standard Receptacles Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. 1 120 V 15 A AC Receptacles GFCI-2 And GFCI-3 GFCI-2 and GFCI-3 supply 60 Hz 34 single-phase power at weld/power speed. Maximum output from each receptacle is 2.4 kVA/kW (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 t
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5-2. Optional Auxiliary Power Receptacles If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord. Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. 1 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 60 Hz single- phase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW (CSA:
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5-3. Wiring Optional 240 Volt Plug 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 7 When wired for 120 V loads, each duplex receptacle shares a load Current Available In Amperes with one half of 240 V receptacle. 240 V Each 120 V Duplex 2 Plug Wired For 240 V, 2-Wire 1 Receptacle* Receptacle Load 3 Neutral (Silver) Terminal 3 35 0 4 4 Load 1 (Brass)Terminal 30 5 25 10 5 Load 2 (Brass) Terminal 20 15 6 Ground
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SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Stop engine before maintaining. See also Engine Manual and mainte- Recycle engine fluids. nance label. Service engine more often if used in severe conditions. 8 h Check Fluid Wipe Up Levels. Spills. See Section 3-4. 20 h Check And Service Air Clean Optional Cleaner Foam Spark Arrestor Element. See Screen. See Section 6-3. Section 6-7. 50 h Clean And Tighten Weld Terminals. 100 h Check Air Change Oil. See Check Cleaner Secti
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6-2. Maintenance Label KOHLER CH18 GAS ENGINE Air Filter Service . . . . 100 hours or less – see Owner’s Manual See Engine Manual for complete engine care. Give Air Filter Element . . . . MILLER 067 272, Kohler 4708303 engine Specification and Serial Number when ordering parts. Air Filter Wrapper . . . . MILLER 067 273, Kohler 2408302 Check °C °F daily. +100 +30 12 Volt Battery . . . . . . BCI Group 58 + +20 Cranking Performance at 0°F (-18°C) . . . . 430 Amps min. +10 To Drain Oil: +32 0 Push A
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6-4. Changing Engine Oil, Oil Filter, And Fuel Filter Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter 4 Oil Fill Cap 5 Oil Dipstick Change engine oil and filter ac- cording to engine owner’s manual. 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). 4 6 Fuel Filter 7 Fuel Line Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. Start engine, and che
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6-5. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 ± 50 rpm Start engine and run until warm. Turn Fine Adjust control to 10. 3700 ± 50 rpm Idle Speed Adjustment Move Engine Control switch to Run/Idle position. 1 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 5 idle speed screw so solenoid can
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6-6. Overload Protection Stop engine. 1 Fuse F1 (See Parts List) F1 protects the generator excita- tion circuit. If F1 opens, there will be no/low weld and auxiliary power output. 1 2 Fuse F6 (See Parts List) F6 protects the engine wiring har- ness. If F6 opens, the engine does not crank. Replace any open fuses. Reinstall panel before operating unit. If any fuse continues to open, contact Factory Authorized 2 Service Agent. Tools Needed: 3/8 in ST-801 226-A / Ref. ST-801 221 6-7. Inspecting
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6-8. Troubleshooting A. Welding Trouble Remedy No weld output. Check control settings. Check weld connections. Check fuse F1 and replace if open (see Section 6-6). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2. Check plug PLG6 connection. Low weld output. Check fuse F1 and replace if open (see Section 6-6). Check control settings. Check and adjust engine speed (see Section 6
