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TABLE OF CONTENTS

SECTION 8

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MAINTENANCE (ROBIN-POWERED UNITS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Overload Protection (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . .

8-6. Adjusting Engine Speed (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Servicing Optional Spark Arrestor (Robin-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9

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MAINTENANCE

−

(KOHLER-POWERED UNITS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Maintenance Label (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner (Kohler

−

Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . .

9-5. Adjusting Engine Speed (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Overload Protection (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10

−

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Welding Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Generator Power Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Engine Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11

−

PARTS LIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Recommended Spare Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12

−

ELECTRICAL DIAGRAMS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13

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GENERATOR POWER GUIDELINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14

−

STICK WELDING (SMAW) GUIDELINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15

−

MIG WELDING (GMAW) GUIDELINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder

. . . . . . . . . . . . . . . . . . . . .

15-2. Holding And Positioning Welding Gun

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3. Conditions That Affect Weld Bead Shape

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-4. Gun Movement During Welding

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-5. Poor Weld Bead Characteristics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-6. Good Weld Bead Characteristics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-7. Troubleshooting

−

Excessive Spatter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-8. Troubleshooting

−

Porosity

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-9. Troubleshooting

−

Excessive Penetration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-10.

Troubleshooting

−

Lack Of Penetration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-11.

Troubleshooting

−

Incomplete Fusion

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-12.

Troubleshooting

−

Burn-Through

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-13.

Troubleshooting

−

Waviness Of Bead

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-14.

Troubleshooting

−

Distortion

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-15.

Common MIG Shielding Gases

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Содержание Bobcat 250

Страница 1: ...s Description Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 4419 211 392M 2007 05 Visit our website at www MillerWelds co...

Страница 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Страница 3: ...ions 12 4 2 Dimensions Weights and Operating Angles 13 4 3 Dimensions For Units With Optional Running Gear 13 4 4 Fuel Consumption Robin Powered Units 14 4 5 Fuel Consumption Kohler Powered Units 14 4...

Страница 4: ...k Arrestor Kohler Powered Units 42 SECTION 10 TROUBLESHOOTING 43 10 1 Welding Troubleshooting 43 10 2 Generator Power Troubleshooting 43 10 3 Engine Troubleshooting 44 SECTION 11 PARTS LIST 45 11 1 Re...

Страница 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Страница 6: ...ing 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 o...

Страница 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Страница 8: ...ge 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 t...

Страница 9: ...tion 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 Assoc...

Страница 10: ...l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises da...

Страница 11: ...provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pe...

Страница 12: ...oquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et s...

Страница 13: ...me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut...

Страница 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Страница 15: ...onal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standa...

Страница 16: ...CTION 4 SPECIFICATIONS 4 1 Weld Power and Engine Specifications This unit uses either a Robin EH 65 or a Kohler CH 23 engine Differences between models are noted throughout this manual Welding Mode We...

Страница 17: ...mm 4 Holes G tip C 1 3 4 in 44 mm E D 6 1 16 in 154 mm E F 25 E 32 3 4 in 832 mm 25 F 45 3 8 in 1153 mm 25 25 G 13 32 in 10 mm Dia 25 Weight Robin PoweredUnit 560 lb 254 kg Robin PoweredUnit 560 lb 25...

Страница 18: ...about 20 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 3 4 gal lon per hour or about 16 hours of operation 4 5 Fuel Consumption Kohler Powered Units 220 181 On a typical...

Страница 19: ...4 6 Volt Ampere Curves 200 296 200 297 200 298 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall b...

Страница 20: ...nerator power curve shows the generator power in amperes available at the receptacles Continuous Welding 4 8 Duty Cycle 200 293 Duty cycle is the percentage of 10 minutes that unit can weld at rated l...

Страница 21: ...Do not install unit where air flow is restricted or engine may overheat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Term...

Страница 22: ...o monitor oil level Open top service door Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler neck empty to...

Страница 23: ...oil level Open top service door Fuel To help prime the fuel system at ini tial start up fill tank with fresh fuel see maintenance label for specifi cations Always leave filler neck empty to allow roo...

Страница 24: ...exhaust outlet Point exhaust pipe in desired direction but always away from front panel and direction of travel Be sure to tighten exhaust clamp nuts Exhaust clamp supplied with muffler Tools Needed...

Страница 25: ...ly connect weld cables may cause exces sive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied n...

Страница 26: ...0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2...

Страница 27: ...Negative hours indicated when past rec ommendedoil change interval To reset cycle Engine Control switch from Run Idle to Run three times within five sec onds engine off 4 Weld Process Selector Switch...

Страница 28: ...from piston ring blow by if the engine is exten sively idled This may cause vacuum line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in...

Страница 29: ...cable to Elec trode terminal on welding generator Be sure to use the correct size weld cables see Section 5 7 For best performance set the Coarse Range switch to the low est range that covers the des...

Страница 30: ...possible to drive rolls without touching Tighten knob See wire feeder manual for wire thread ing procedure Insert gun trigger plug item 4 into matching receptacle and tighten threaded collar Connect...

Страница 31: ...t gun end through opening in feed er and position as close as possible to drive rolls without touching Tight en knob See wire feeder manual for wire threading procedure Insert gun trigger plug item 4...

Страница 32: ...gger control plug item 11 into weld control receptacle Tighten threaded collar Connect ac power cord item 12 to 120 volt ac receptacle on welding generator Connect gas hose from spoolgun to regula tor...

Страница 33: ...opens the receptacle does not work Press button to reset supplementary protector If supplementary protector continues to open contact Factory Authorized Service Agent 7 Optional 120 V 20 A AC GFCI Re...

Страница 34: ...0 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load 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...

Страница 35: ...fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 2 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 8 7 Spark Arrestor Scre...

Страница 36: ...A complete Parts List is available at www MillerWelds com OM 4419 Page 32 8 2 Maintenance Label Robin Powered Units...

Страница 37: ...Stop engine Disconnect negative battery cable 1 Fuse F1 See Section 11 1 F1 protects the weld excitation winding from overload If F1 opens weld output stops or is low 2 Fuse F2 See Section 11 1 F2 pr...

Страница 38: ...r Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4...

Страница 39: ...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 Tight en mou...

Страница 40: ...ine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing 1 4 in 1 Tools Needed Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025...

Страница 41: ...e engine fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 3 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 9 7 Spark Arre...

Страница 42: ...A complete Parts List is available at www MillerWelds com OM 4419 Page 38 9 2 Maintenance Label Kohler Powered Units...

Страница 43: ...engine with out air cleaner or with dirty element 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleane...

Страница 44: ...ilter Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 5...

Страница 45: ...on 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...

Страница 46: ...se F6 See Section 11 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating If a fuse opens it usually indi cat...

Страница 47: ...ut Check control settings Check engine speed and adjust if necessary see Section 8 6 or 9 5 Erratic weld output Check control settings Tighten and clean connections to electrode and workpiece Use dry...

Страница 48: ...Check low oil pressure shutdown switch Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 FS1 optional on Robin powered units Engine starts but stops when Engine Control switch retu...

Страница 49: ...de icer product Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath er engine starts and goes to idl...

Страница 50: ...OM 4419 Page 46 SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For Welding Generator...

Страница 51: ...OM 4419 Page 47 228 460 A...

Страница 52: ...ctric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Groun...

Страница 53: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Страница 54: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Страница 55: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Страница 56: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Страница 57: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Страница 58: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Страница 59: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Secti...

Страница 60: ...LET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 1...

Страница 61: ...14 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 14 7 Good Weld Bead Characteristics...

Страница 62: ...rrect Angle 14 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weav...

Страница 63: ...4 14 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be f...

Страница 64: ...Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface bef...

Страница 65: ...dirt from work surface before welding 14 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Caus...

Страница 66: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 14 21 Troubleshooting Distortion Distortion contraction of weld me...

Страница 67: ...ptional gas valve Voltage Sensing Wire Feeder Constant Current CC Or Constant Voltage CV Power Source Work Lead Electrode Lead Workpiece Work Clamp Voltage Sensing Clamp Gun 802 488 15 2 Holding And P...

Страница 68: ...lectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIO...

Страница 69: ...Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 15 5 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Sligh...

Страница 70: ...nsufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place noz...

Страница 71: ...n Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pai...

Страница 72: ...pport hand on solid surface or use two hands 15 14 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Страница 73: ...uminum Short Circuiting Aluminum Argon All Positions5 All Positions Argon 1 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 2 O2 Flat Horizontal5 Fillet Flat Horizontal5 Fillet Argon 5 O2 Fla...

Страница 74: ......

Страница 75: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Страница 76: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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