Bobcat225D Plus

TM-404H July 2004
Eff. w/Serial Number KG076022
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding

Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)

Welding
Description
Engine Driven Welding Generator
Bobcat 225D

Visit our website at

www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARNING
2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 This product, when used
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 for welding or cutting,
produces fumes or
3-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 gases which contain
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 chemicals known to the
3-3. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 State of California to
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cause birth defects and,
in some cases, cancer.
3-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(California Health &
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Code Section
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 25249.5 et seq.)
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-3. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WARNING
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Battery posts, terminals
and related accessories
4-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
contain lead and lead
SECTION 5 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 compounds, chemicals
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 known to the State of
California to cause
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 cancer and birth defects
6-1. Standard Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 or other reproductive
6-2. CSA Receptacle Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 harm. Wash hands after
6-3. GFCI, South African, And Australian Auxiliary Power Receptacle Options . . . . . . . . . . . . . . 14 handling.
6-4. Wiring Optional 120/240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CALIFORNIA
7-1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Proposition 65
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warning
7-3. Inspecting And Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7-4. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Diesel engine exhaust
and some of its con-
7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 stituents are known to
7-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 the State of California
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to cause cancer, birth
defects, and other
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 reproductive harm.
9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9-2. Troubleshooting Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-3. Waveforms For Section 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-4. Idle Module PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9-5. Troubleshooting Flowcharts For Idle Module PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9-6. Replacing Brushes And Cleaning Slip Rings Prior To Serial No. KH356820 . . . . . . . . . . . . . 36
9-7. Replacing Brushes And Cleaning Slip Rings Eff/w Serial No. KH356820 Thru KK327893 . . 37
9-8. Replacing Brushes And Cleaning Slip Rings Eff w/ Serial No. KK237894 . . . . . . . . . . . . . . . 38
9-9. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 10 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-1. Disassembly Of Unit Prior To Serial No. KK327894 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-2. Disassembly Of Generator Prior To Serial No. KK327894 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10-3. Disassembly Of Unit Effective With Serial No. KK327894 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10-4. Disassembly Of Generator Effective With Serial No. KK327894 . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 12 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 13 − PARTS LIST FOR KG076022 THRU KH559130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 14 − PARTS LIST FOR KH559131 THRU KJ274741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SECTION 15 − PARTS LIST FOR KJ274742 THRU KK327893 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 16 − PARTS LIST FOR KK327894 THRU LA236778 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SECTION 17 − PARTS LIST FOR LA236779 THRU LB064992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SECTION 18 − PARTS LIST FOR LB064993 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
safety_rtm 7/99 / OM-404T
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see STATIC (ESD) can damage PC boards.
the symbol, watch out, and follow the related instructions to
D Put on grounded wrist strap BEFORE handling
avoid the hazard.
boards or parts.
Y Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.

ENGINE EXHAUST GASES can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un- D Do not breathe exhaust fumes.
less the procedure specifically requires an en- D Use in open, well-ventilated areas, or vent ex-
ergized unit. haust outside and away from any building air in-
D Insulate yourself from ground by standing or working on dry insu- takes.
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping D Stop engine and let it cool off before checking or
engine on inverters. adding fuel.
D Stop engine on inverter and discharge input capacitors according D Do not add fuel while smoking or if unit is near
to instructions in Maintenance Section before touching any parts. any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.

D Keep away from moving parts such as
fans, belts, and rotors.
BATTERY EXPLOSION can BLIND.
D Have only qualified people remove
guards or covers for maintenance and D Always wear a face shield, rubber gloves, and
troubleshooting as necessary. protective clothing when working on a battery.
D Keep hands, hair, loose clothing, and tools away from mov- D Stop engine before disconnecting or connect-
ing parts. ing battery cables.
D Before working on generator, remove spark plugs or injec- D Do not allow tools to cause sparks when working on a battery.
tors to keep engine from kicking back or starting. D Do not use welder to charge batteries or jump start vehicles.
D Block flywheel so that it will not turn while working on gener- D Observe correct polarity (+ and −) on batteries.
ator components.
D Disconnect negative (−) cable first and connect it last.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face
D Do not tip battery.
shield during servicing.
D Replace damaged battery.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing. D Flush eyes and skin immediately with water.
Bobcat 225D Plus TM-404 Page 1

STEAM AND HOT COOLANT can burn. TILTING OR TIPPING can cause injury.
D If possible, check coolant level when engine is D Do not put any body part under unit while lifting.
cold to avoid scalding. D Always use proper equipment (hoists, slings,
D Always check coolant level at overflow tank, if chains, blocks, etc.) of adequate capacity to lift
present on unit, instead of radiator. and support components (stator, rotor, engine,
etc.) as needed during job.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two PINCH POINTS can injure.
statements. D Be careful when working on stator and rotor assemblies.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap. H.F. RADIATION can cause interference.
MAGNETIC FIELDS can affect pacemakers. D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Pacemaker wearers keep away from servicing communications equipment.
areas until consulting your doctor. D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
FALLING UNIT can cause injury. D If notified by the FCC about interference, stop using the equip-
ment at once.
D Use equipment of adequate capacity to lift and
support unit and components. D Have the installation regularly checked and maintained.
D Use lifting eye to lift unit only, NOT running D Keep high-frequency source doors and panels tightly shut, keep
gear, gas cylinders, or any other accessories. spark gaps at correct setting, and use grounding and shielding to
D Securely attach components to lifting equip- minimize the possibility of interference.
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
HOT PARTS can cause severe burns.
D Reduce current or reduce duty cycle before
D Allow cooling period before servicing. starting to weld again.
D Wear protective gloves and clothing when D Do not block or filter airflow to unit.
working on a hot engine.
D Do not touch hot engine parts bare-handed.
READ INSTRUCTIONS.
SHOCK HAZARD from testing. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Stop engine before making or changing meter
D Consult the Owner’s Manual for welding safety
lead connections.
precautions.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip. D Use only genuine replacement parts.
D Read instructions for test equipment. D Reinstall injectors and bleed air from fuel system according to
engine manual.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from
committee’s judgment, has not demonstrated that exposure to power- operator as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-404 Page 2 Bobcat 225D Plus

SECTION 2 − DEFINITIONS
2-1. Symbol Definitions
Fast Fast/Slow
Stop Engine Slow (Idle)
(Run, Weld/Power) (Run/Idle)
Start Engine Glow Plug Temperature Fuel
Check Injectors/ Check Valve

Engine Oil Battery (Engine)
Pump Clearance
Engine
Read Operator’s
Manual A Amperes
V Volts
Gas Metal Arc Shielded Metal Arc Gas Tungsten Arc

Circuit Breaker
Welding (GMAW) Welding (SMAW) Welding (TIG)
Alternating Current
Positive Negative Output
(AC)
s
Protective Earth
h
Time Hours Seconds
(Ground)
Do not switch while Welding Arc

Work Connection
welding (Electrode)
SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Rated Maximum
Welding Weld Output Generator Power Fuel
Welding Open Circuit Engine
Mode Range Rating Capacity
Output Voltage
225 A, 25 V,
CC/AC 50 − 225 A 100% Duty 80
Cycle
Peak: 8.5 kW/kVA
210 A, 25 V, Continuous: 8 kVA/kW, Deutz/Ruggerini MD-151

CC/DC 50 − 210 A 100% Duty 72 Single-Phase, 10 gal (38 L)
Air-Cooled, Two-Cylinder,
Cycle 70/35 A, 120/240 V AC, Tank
Diesel Engine
50/60 Hz,
(while not welding)
200 A, 20 V,
CV/DC 17 − 28 V 100% Duty 33
Cycle

3-2. Dimensions, Weights, and Operating Angles
Dimensions A
B
Height 31 in (787 mm)
C
Width 18-3/4 in (476 mm)
Y Do not exceed tilt angles or engine could
Depth 46 in (1164 mm) D be damaged or unit could tip.
Y Do not move or operate unit where it could
A 18 in (457 mm) G
tip.
4 Holes
B 16-1/2 in (419 mm)
C 3/4 in (19 mm) E

F
D 3-1/8 in (79 mm)
E 32-3/4 in (832 mm) 25°
F 45-1/2 in (1156 mm)

25° 25°
G 13/32 in (10 mm) Dia. 25°
Weight
564 lb (256 kg) Engine End 800 426
3-3. Generator Power Curve

The generator power curve shows
the generator power in amperes
available at the receptacles.
182 719
3-4. Fuel Consumption

The fuel consumption curve
shows typical fuel use under
weld or power loads.
SB-145 981

3-5. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
100% Duty Cycle at 225 Amperes CC/AC, 210 Amperes CC/DC, 200 Amperes CV/DC
SB-119 454-A
3-6. Volt-Ampere Curves

The volt-ampere curve shows the
A. For CC/AC Mode minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
B. For CC/DC Mode C. For CV/DC Mode
166 024-A / 166 025-A / 166 026-A

SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Y Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Y Always securely fasten weld-
Y Do not lift unit from end. ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
OR Y Do not mount unit by support-
ing the base only at the four
mounting holes. Use cross-
supports to adequately sup-
port unit and prevent damage
to base.
Y Always ground generator
Location frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Y If unit does not have GFCI re-
ceptacles, use GFCI-protected
OR extension cord.
Mounting:
1 Cross-Supports
Mount unit on flat surface or use
Mounting cross-supports to support base.
Grounding:
2 Equipment Grounding Terminal
(On Front Panel)
3 Grounding Cable (Not Supplied)
4 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
OR
Inadequate support.
Y Do not use flexible mounts. 1
Grounding 2
GND/PE 3
Electrically bond generator frame to

vehicle frame by metal-to-metal contact.
Airflow Clearance 18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)
18 in 18 in
(460 mm) (460 mm)
install2 5/02 − Ref. 800 652 / Ref. 800 477-A / 803 274

4-2. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Oil may be added at either oil fill.
. This unit has a low oil pressure
shutdown switch. However,
some conditions may cause
engine damage before the en-
Full gine shuts down. Check oil lev-
el often and do not use the oil
pressure shutdown system to
monitor oil level.
Fuel Gauge
Diesel Follow run-in procedure in engine
On Tank
manual. If unburned fuel and oil col-
lect in exhaust pipe during run-in,
see Section 12.
Fuel
Y Do not use gasoline. Gaso-
line will damage engine.
Add fresh diesel fuel before starting
engine the first time (see mainte-
nance label for specifications). Fill
fuel tank to bottom of filler neck to
allow room for expansion.
Do not run out of fuel or air enters
fuel system and causes starting
problems. See engine manual to
bleed air from fuel system.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).
. To improve cold weather
starting:
Full
Keep battery in good condition.
Store battery in warm area off

concrete surface.
Use fuel formulated for cold

weather (diesel fuel can gel in
cold weather). Contact local
fuel supplier for fuel informa-
tion.
Use correct grade oil for cold

weather.
Ref. 151 983 / Ref. 801 331-G

4-3. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection − Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 bottom of well (maximum).
Y Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6 Battery Charger
Y Read and follow all instruc-
2 tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
. When electrolyte is low, add

only distilled water to cells to
maintain proper level.
5 A For 30 Minutes
OR
+
−
Tools Needed:
30 A For 12 Minutes
drybatt1 2/96 − S-0886

4-4. Connecting The Battery
Y Connect negative (−)

cable last.
+ −
Tools Needed:
3/8, 1/2 in Ref. 800 394-B / Ref. 192 785 / Ref. S-0756-D
4-5. Connecting To Weld Output Terminals

1 Work Weld Output Terminal
2 Electrode Weld Output
Terminal
Connect work cable to Work
Tools Needed: terminal.
3/4 in Connect electrode holder cable or
electrode weld cable to Electrode
terminal for Stick and MIG welding.
Connect torch cable to Electrode
terminal for TIG welding.
Use Process Selector switch to
select type of weld output (see
Section 5-1).
1 2
801 458-A / Ref. 192 785

4-6. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
* Thischart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**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.
( ) = mm2 for metric use S-0007-E−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes

SECTION 5 − OPERATING WELDING GENERATOR
5-1. Front Panel Controls
5 6 3 7 2
Glow Plug Time

8
t Right Side
0s 70°F (21°C)
10 s 32°F (0°C)
20 s −4°F (−20°C)
Ref. 192 785 / Ref. 801 434

1 Engine Control Switch In Run/Idle position and Engine Control 5 Coarse Adjust Switch
Use switch to start engine, select speed, and switch in Run, engine runs at weld/power Use switch to select weld amperage range
stop engine. In Run/Idle position, engine speed. when Weld Process Selector switch is in
runs at idle speed at no load, and weld/power To start: move idle lock switch and engine Stick/Tig position, or voltage range when
speed under load. In Run position, engine control switch to Start. Release engine con- switch is in Wire position.
trol switch when engine starts.
runs at weld/power speed. . For best arc starts, use lowest amper-
. Place switch in Run position to operate . If the engine does not start, let engine age range possible.
most GMAW equipment. come to a complete stop before attempt- 6 Fine Adjust Control
2 Glow Plug Switch (Optional) ing restart.
Use control to select weld amperage (Stick/
If necessary, push switch up before start-up Move idle lock switch to Run/Idle after Tig) or voltage (Wire) within the range se-
(see table). engine warms. lected by the Coarse Adjust switch. Control
To stop: move engine control switch to Off. may be adjusted while welding. Weld output
3 Idle Lock Switch
4 Weld Process Selector Switch would be 110 amps DC with control settings
Use switch to lock engine in idle speed as shown (50% of 70 to 150). Scale is for ref-
during start-up. In Start position and Engine Use switch to select type of weld output. erence only.
Control switch in Run or Run/Idle, engine is Use a positive (+) position for Direct Current 7 Engine Hour Meter
locked in idle speed. In Run/Idle position and Electrode Positive (DCEP) and a negative
Engine Control switch in Run/Idle, engine (−) position for Direct Current Electrode Neg- 8 Manual Shutoff Lever
runs at idle speed at no load and weld/power ative. Use AC position for alternating Turn lever counterclockwise to stop engine
speed under load. current. if engine control switch does not work.

SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. Standard Receptacles
ceptacles, use GFCI-
protected extension cord.
. Generator power decreases

as weld current increases.
6 Set Fine Adjust control R1 at 10

4 5 for full generator power.
1 120 V 20 A AC Duplex
Receptacle RC3
Receptacle RC2
RC3 and RC2 supply 60 Hz single-
phase power at weld/power speed.
2 Maximum output from RC3 or RC2
3
is 2.4 kVA/kW (CSA: 1.8 kVA/kW).
1 3 120/240 V 50 A AC
Receptacle RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed.
Maximum output is 8.5 kVA/kW.
4 Circuit Breaker CB3
6 Circuit Breakers CB1 And
CB2
CB3 protects RC2 and CB4
protects RC3 from overload. If a cir-
cuit breaker opens, the receptacle
does not work. Press button to re-
set breaker.
CB1 and CB2 protect RC1 from
overload. If CB1 or CB2 opens,
7 RC1 and one of the 120 volt
SIMULTANEOUS WELDING AND POWER
WITH FINE ADJUST SET AT 10 receptacles does not work. 120
volts may still be present at RC1.
120V 240V Y Power is still present at the

Weld Current Total Power 240 volt receptacle when
Receptacle Receptacle
In Amperes In Watts only one circuit breaker
Amperes Amperes
trips.
210 1000 8 4
Unplug power cord before
140 4300 36 18 attempting to service acces-
sories or tools.
90 6000 50 25
Combined output of all receptacles
limited to 8.5 kVA/kW rating of the
generator.
Ref. S-166 360-A
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
15 A is available at the 240V
receptacle:
2 x (120 V x 20 A) + (240 V x 15 A)
= 8.4 kVA/kW
7 Generator Power While
Welding Chart (For Reference
Only)
Ref. 192 785

6-2. CSA Receptacle Option
ceptacles, use GFCI-protected
extension cord.
1 120/240 V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maxi-
mum output is 10 kVA/kW.
1 5 2 6 3 2 120 V 20 A AC Duplex Recep-
tacle RC2
3 120 V 20 A AC Duplex Recep-
tacle RC3
RC2 and RC3 supply 60 Hz single-
Maximum output from RC2 or RC3 is
2.4 kVA/kW.
CB1 protects the ac receptacles from
overload. If CB1 opens, the ac recep-
tacles do not work.
. Move CB1 toggle switch to On
position to reset circuit breaker.
CB2 protects RC2 and CB3 protects
RC3 from overload. If a circuit break-
er opens, the receptacle does not
work.
. Press button to reset circuit
breaker.
4 limited to 8.5 kVA/kW rating of the
generator.
EXAMPLE: If 20 A is drawn from
7 each 120 V duplex receptacle, only
15 A is available at the 240V
receptacle:
2 x (120 V x 20 A) + (240 V x 15 A) =
8.4 kVA/kW
SIMULTANEOUS WELDING AND POWER
WITH FINE ADJUST SET AT 10 7 Generator Power While Welding
Label
Weld Current Total Power 120V 240V

Receptacle Receptacle
In Amperes In Watts
Amperes Amperes
210 1000 8 4
140 4300 36 18
90 6000 50 25
See Owner’s Manual for additional information.

S-166 360-A
203 683

6-3. GFCI, South African, And Australian Generator Power Receptacle Options
ceptacles, use GFCI-
protected extension cord.
. Generator power decreases as

weld current increases.
Set Fine Adjust control R1 at 10

for full generator power.
limited to 8.5 kVA/kW rating of the
generator.
1
GFCI Receptacle Option
1 120 V 20 A AC GFCI Recep-
tacles GFCI2 And GFCI3
GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/kW.
Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
4 damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.
. At least once a month, run

5 engine at weld/power speed
and press Test button to verify
GFCI is working properly.
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 Re-
2 ceptacles RC1, RC2, And
RC3
Receptacles supply 60 Hz single-
Maximum output from each recep-
tacle is 3.6 kVA/kW.
4 Circuit Breakers CB1, CB2,
4 CB3
CB1, CB2, and CB3 protect RC1,
RC2, and RC3 from overload. If a
circuit breaker opens, the recep-
tacle does not work. Press button to
5 reset breaker.
CB4 protects all the receptacles
from overload. If CB4 opens, none
of the receptacles work.
Ref. 192 785 / Ref. 182 441-A / Ref. 181 719-A

6-4. Wiring Optional 120/240 Volt Plug
The plug can be wired for a 240 V,
1 2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
3
1 Plug Wired For 120/240 V,
4 3-Wire Load
7
When wired for 120 V loads, each
Current Available In Amperes duplex receptacle shares a load
with one half of 240 V receptacle.
240 V Each 120 V Duplex 2 Plug Wired For 240 V, 2-Wire
Receptacle* Receptacle 120V Load
120V 5
35 0 3 Neutral (Silver) Terminal
240V
30 5 6
4 Load 1 (Brass)Terminal
25 10 2 5 Load 2 (Brass) Terminal
20 15
15 20 3 6 Ground (Green) Terminal
V x A = Watts 4 7 Amperes Available Using
120/240 V Plug
*One 240 V load or two 120 V loads.
240V
6 5
Tools Needed:
120 813-D
Notes

SECTION 7 − MAINTENANCE
7-1. Maintenance
Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Y Stop engine before maintaining.
Recycle . See also Engine Manual and maintenance label.

engine Maintain more often if used in severe conditions.
fluids. * To be done by Factory Authorized Service Agent.
8h
Check Fluid Service

Wipe Up Air
Levels.
Spills. Filter.
See Section 4-2.
50 h
Clean And
Service Air
Tighten
Filter
Weld
Element.
Terminals.
100 h
Clean Cooling Clean And

System. Tighten
See Engine Battery
Manual. Connections.
200 h
Change Oil. See Change Oil

Section 7-4 And Filter. See
Maintenance Section 7-4.
Label.
Replace Fuel Replace

Check Valve Filter. See Damaged Or
Clearance.* Section 7-4. Unreadable
Labels.
250 h
Check And
Clean Spark
Arrestor.
See Section
7-3.

500 h
Service Welding
Generator Brushes Repair Or Replace Clean/Set
And Slip Rings. Cracked Cables Injectors.*
Service More Often In And Cords.
Dirty Conditions.*
1000 h
Blow Out Or
Vacuum Inside.
Notes

TM-404 Page 18
DEUTZ/RUGGERINI MD151 DIESEL ENGINE
Air Filter Service . . . . . . . 50 hours or less − see Owner’s Manual
See Engine Manual for complete engine care.

Give Engine Specification and Serial Number when ordering parts.
7-2. Maintenance Label
12 Volt Battery . . BCI Group 58 Valve Clearance −Cold

+ Cranking Performance at 0°F Intake . . . 0.006 in (0.15 mm)
To Drain Oil: Exhaust . 0.006 in (0.15 mm)
(-18°C) . . . . . . . . 430 Amps
50
Push And
°C °F
Check +40 +104
daily. Turn CCW
40
1/2 in. ID Hose +30 +86 Engine RPM − No Load Engine Cooling
30
Pull +20 +68 Weld/Power . . . . 3750 Avoid recirculation of air from hot
Recommended +59 Idle . . . . . . . . . . . 2000 air exit to blower intake.
+10
Oil . . . . . . . . . . . . . . API Service Classification
20W
SAE 15W-40
CD, SF/CD, CC/CD or better 0 +32
Oil Change . . . . . . 200 hours or less -10
+5
SAE 10W-30
Oil Filter Change . . normal conditions - 200 hours
10W
or less -20
-18 Injectors . . . . . . . . . . . . . . MILLER 066 852, Deutz 77-644-56
Oil Filter . . . . . . . . . MILLER 066 702,
Deutz 77-175-24 Have only trained technician maintain injection pump and injectors. AIR, WATER,
Multi- Single
Oil Capacity . . . . . . 1.9 qt (1.8 L) or Viscosity Oils Viscosity Oils or GASOLINE will harm the injection system.
2 qt (1.9 L) with filter change
Do NOT
Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 40 min. (.5% max. Sulfur content) use ether.
Primary Fuel Filter . . . . . MILLER 066 113
Secondary Fuel Filter . . . MILLER 066 893, Deutz 77-175-19
Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours −
Diesel see Owner’s Manual
Fill filter with clean fuel before installing − read instructions on filter.
Optional S-173 094-B
Bobcat 225D Plus

7-3. Inspecting And Cleaning Optional Spark Arrestor
Y Stop engine and let cool.
1 Spark Arrestor
2 Cleanout Plug
Remove plug and remove dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Reinstall cleanout plug.
Tools Needed:
5/16 in
Ref. 801 331-G / 800 497 -A / Ref. 192 785

7-4. Changing Engine Oil, Oil Filter, And Fuel Filter
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 accord-
ing to engine Owner’s Manual. Oil
may be added at either oil fill.
6 Fuel Line
4 7 Primary Fuel Filter
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
3 fuel.
5
8 Secondary Fuel Filter
4 Remove filter and install new filter
element according to engine
Owner’s Manual. Replace fuel line
if cracked or worn. Wipe up spilled
fuel.
9 Hand Primer
Push lever 10 to 12 times to prime
injector system.
Start engine and check for fuel
leaks.
Y Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
Tools Needed:
2
8
6 7
Ref. 192 785 / Ref. 801 331-G / 801 434-A / S-0842

7-5. Adjusting Engine Speed
Engine speeds have been factory
set and should not require adjust-
ment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load engine
speeds. If necessary, adjust
speeds as follows:
Idle Speed Adjustment:
2000 rpm 1 Throttle Cable
4
3750 rpm 2 Throttle Cable Stop Screw
Start engine and run at idle speed.
3
Loosen screw and adjust cable until
engine runs at correct idle speed.
Do not allow slack in cable. Tighten
screw.
Weld/Power Speed Adjustment:
1 Run engine at weld/power speed.
3 Weld/Power Speed Screw
4 Weld/Power Speed Jam Nut
Loosen jam nut. Turn screw clock-
wise to decrease speed and coun-
terclockwise to increase speed.
2 Tighten jam nut.
Y Stop engine.
Tools Needed:
1/4 in, 8mm

Right Side
Ref. 801 434-A
7-6. Overload Protection
A. Time Delay Relay CB7 And Fusible Link (Optional With Glow Plug)
Internal time delay relay CB7 and the fusible link protect the optional glow plug system from overheating. If glow plugs
overheat, CB7 automatically stops the heating process. Wait one minute for CB7 to automatically reset before using
glow plugs.
If the engine is hard to start in cold weather, check the fusible link and replace if open. If CB7 or the fusible link
continues to open, check for damaged plug or shorted lead.
B. Circuit Breaker CB8

CB8 protects the idle solenoid. If
CB8 opens, engine drops to idle
speed.
Check throttle solenoid and cable
for obstructions and throttle linkage
for proper adjustment. Press button
to reset circuit breaker.
1
If CB8 continues to open, check
throttle solenoid and cable for ob-
structions, and throttle linkage for
proper adjustment.
801 458-A / Ref. 192 785
C. Fuse F1
Y Stop engine and disconnect

battery negative (−) cable.
Remove top cover.
1 Fuse F1 (See Parts List For
Rating)
1 F1 protects the exciter stator from
overload.
Replace F1 if open. Reinstall top
cover before operating unit.
If F1 continues to open, check inte-
grated rectifier SR2, capacitor C1,
and the rotor.
Tools Needed:
3/8, 1/2 in
Ref. 801 477-C

Notes

SECTION 8 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
field.
5 4
2 Revolving Field
Fine Adjust Integrated
Turns at 3750 rpm maximum for Control Rectifier
weld and power. The speed and ex- R1 SR2
citation current of the field coils de-
termine voltages in stator windings.
3 Stator Windings
5
Supply power to exciter, generator
power, and weld circuits.
Resistor
4 Integrated Rectifier SR2 R2
3
Changes ac output from stator
winding to dc to supply excitation
current to revolving field. Exciter
1 2
Generator Power
5 Fine Adjust Control R1,
Resistor R2 Revolving
Engine Stator Windings
Changes output of stator weld Field
windings by adjusting field current
level in revolving field.
Weld
6 Current Transformer CT1
Senses output from either genera-
tor power or weld windings, and
signals PC1 to increase to or
maintain weld speed (3750 rpm). 9 8 7
7 Idle Module PC1
Throttle
Controls engine speed. Without a Solenoid TS1 Idle Lock Idle Module
signal from CT1, it lowers engine (Pull To Weld) Switch S5 PC1
speed to idle (2000 rpm).
8 Idle Lock Switch S5
Start position locks engine speed at
idle. Run/Idle position lets PC1
control engine speed.
9 Throttle Solenoid TS1
Increases engine speed to 3750
rpm when energized.
CB2
Protect generator power recep-
tacles RC1, RC2, and RC3, and op-
tional plasma cutter receptacle
RC40 from overload.
CB4
Protect generator power recep-
tacles RC2 and RC3 from overload.
12 generator Power Receptacles
RC1, RC2, And RC3
Provide connection points and
power for auxiliary equipment.
13 Control Relay CR10
Energizes when plasma cutter is
connected to RC40 to disable gen-
erator power receptacles.
14 Plasma Cutter Receptacle
RC40
Provides connection point for Lynx
Plasma Cutter option.

15 Reactor AC-Z
Tapped reactor limits weld output
and provides coarse ranges.
16 Coarse Adjust Switch S3
Selects coarse range of weld
output from AC-Z.
17 Main Rectifier SR1
13♦ 14♦
Changes ac weld current to dc.
Plasma Cutter
Control Relay Receptacle 18 Stabilizer DC-Z
CR10 RC40 Smooths out dc current to weld out-
put terminals.
19 Weld Process Selector Switch
S1
Selects type and polarity of weld
6 10 11 12 output.
Generator Power 20 Weld Output Terminals
Circuit Breakers Circuit Breakers Receptacles
CB1 And CB2 CB3 And CB4 RC1, RC2, And RC3 Provide ac or dc weld output.
Current
Transformer 15
CT1
Reactor
AC-Z
16 19 20
Coarse Adjust AC Weld Process Electrode Weld

Switch S3 Selector Output Terminal
Switch S1
DC Electrode
17
Main 20 Work
Rectifier
SR1
Work Weld
Output Terminal
18
Stabilizer
DC-Z
AC Or DC Control Circuits
Weld Current Circuit
Mechanical Coupling
Magnetic Coupling
♦ Optional

SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting Tables
. See Section 9-2 for test points and

values and Section 13 and follo-
wing for parts location.
A. Welding
Trouble Remedy
No weld output. Check control settings.
Check weld connections.
Check fuse F1, and replace if open (see Section 7-6C).
Be sure all equipment is disconnected from generator power receptacles when starting unit.
Check plug PLG6 connection.
Check resistance and connections of resistor R2; R2 is 6 ohms ±10%. Replace R2 if necessary.
Prior to Serial No. KH426280, adjust R2 if replaced (see Section 9-9).
Check integrated rectifier SR3, and replace if necessary.
Disconnect leads 24 and 33 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Clean slip rings, and install new brushes if necessary (see Section 9-6, 9-7, or 9-8).
Check main rectifier SR1, and replace if necessary.
Check reactor AC-Z for signs of failure. Check continuity across windings, and check for proper con-
nections. Replace AC-Z if necessary.
Check capacitor C1 for a short or open, and check for proper connections. Replace C1 if necessary.
Low weld output. Check control settings.
Increase Fine Adjust control R1 setting.
Clean air cleaner (see engine manual).
Check and adjust engine speed (see Section 7-5).
Disconnect stator leads 28 and 29 and check for continuity between leads. Replace stator if
necessary.
necessary.

Trouble Remedy
High weld output. Decrease Fine Adjust control R1 setting.
Check resistance and connections of suppressor R3, VR1 if high open-circuit voltage is present. R3
is 1000 ohms ±10%. Replace R3, VR1 if necessary.
Prior to Serial No. KH426280, adjust resistor R2 (see Section 9-9).
Erratic weld output. Check control settings.
Be sure electrode is dry and proper type for SMAW and GTAW.
Tighten and/or clean connections to electrode and workpiece.
Remove excessive coils from weld cables.
Check internal and external connections to weld output terminals.
Check leads and connections at Weld Process Selector switch S1, Coarse Adjust switch S3, and
Fine Adjust control R1.
Check stabilizer DC-Z for signs of failure. Check continuity across windings, and check for proper
connections. Replace DC-Z if necessary.
B. Generator Power
Trouble Remedy
No output at generator power recep- Reset circuit breakers CB1, CB2, CB3, or CB4 (see Section 6-1).
tacles RC1, RC2, and RC3.
Press optional GFCI receptacle reset button (see Section 6-3).
Check plug PLG6 connection.
necessary.
Disconnect stator leads 28 and 29 and check for continuity between leads. Replace stator if
necessary.
Disconnect power leads 51 and 53 and check for continuity between leads. Replace stator if
necessary.
Turn off optional Lynx plasma cutter. Generator power is not available from receptacles RC1, RC2,
and RC3 when the plasma cutter is connected to RC40.
Check optional control relay CR10 coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR10 if necessary.

Trouble Remedy
Low or high power output at generator Increase Fine Adjust control R1 setting if low power output.
power receptacles RC1, RC2, and
RC3.
Erratic power output at generator pow- Check fuel level (see Section 4-2).
er receptacles RC1, RC2, and RC3.
Check receptacle wiring and connections.
Check governor according to engine manual.
No output at optional ac power recep- Reset circuit breakers CB1 and/or CB2.
tacle for the Lynx Plasma Cutter
(RC40); Lynx Power Light does not go
on when Lynx is turned on.
Check optional control relay CR10 coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR10 if necessary.
Low output at optional ac power recep- Run welding generator at weld/power speed.
tacle for the Lynx Plasma Cutter
(RC40); Lynx unable to cut thick
material.
Turn welding generator Fine Adjust control to 10 (max).
C. Engine
Trouble Remedy
Engine will not crank. Check plug PLG4 connection and plug PLG8 connection.
Check battery voltage.
Check battery connections, and tighten if necessary.
Check continuity and connections of Engine Control switch S2, and replace if necessary.
Engine will not start. Check fuel level (see Section 4-2). Check fuel system components.
Check battery and engine charging system.
Check oil level (see Section 4-2). Check Low Oil Pressure Shutdown switch S4 (see engine manual
for location).
Check fuel solenoid for proper coil voltage and connections. Check continuity of coil. Replace fuel
solenoid if necessary (see engine manual for location).
Check optional glow plug system fusible link, and replace if open (see Section 7-6A).
Wait one minute for optional glow plug system time delay relay CB7 to reset (see Section 7-6A).
Check coil voltage and connections of optional glow plug system relay CR2. Check continuity of coil
and condition of contacts. Replace CR2 if necessary.
Engine starts, but stops when Engine Check oil level. Check Low Oil Pressure Shutdown switch S4 (see engine manual for location).
Control switch S2 returns to Run
position.

Trouble Remedy
Battery discharges between uses. Clean battery terminals and posts with baking soda solution; rinse with clear water.
Periodically recharge battery (approximately every three months).
Check battery, and replace if necessary.
Check Voltage Regulator according to engine manual.
Unstable or sluggish engine speeds. Check fuel level (see Section 4-2). Check fuel system components.
Check throttle linkage for smooth, non-binding operation.
Tune engine according to engine manual.
Engine stops during normal operation. Check fuel level (see Section 4-2). Check fuel system components.
Check oil level. Check Low Oil Pressure Shutdown switch S4 (see engine manual for location).
Periodically recharge battery.
Check battery, and replace if necessary.
Check voltage regulator and connections according to engine manual.
Check continuity of Engine Control switch S2, and replace if necessary.
Engine idles but does not reach weld Reset circuit breaker CB8 (see Section 7-6B).
speed.
Move Idle Lock Switch S5 to Run/Idle position.
Check throttle solenoid TS1 for proper coil voltage and connections. Check continuity of coil. Replace
TS1 if necessary.
Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of
contacts. Replace CR1 if necessary.
Check current transformer CT1, and replace if necessary.
Check idle module PC1 and connections, and replace if necessary.
Engine does not return to idle speed. Remove weld and generator power loads.
Check idle module PC1 and connections, and replace if necessary (see Section 9-4).
Engine uses oil during run-in period; Dry engine according to Owner’s Manual run-in procedure.
wetstacking occurs.
Engine will not stop. Stop engine using manual shutoff lever.
Check continuity of Engine Control Switch S2, and replace if necessary.

9-2. Troubleshooting Circuit Diagram For Welding Generator
Test Equipment Needed:
Optional Plasma Cutter
Receptacle Control Relay CR10 V17
V16
Prior to Serial No.

KH426280, adjust R2
according to
See also Section 9-9
Section
V7, R5 See Section
9-4 for
9-3 for waveforms
PC1 data
G, H
R6 R7
R4
I1
V14
V8, V9, V4, G
V13 V10
V6 R8 V5, H
R9
Idle
Control
Relay CR1 R10
V1, V2, V3,

A, B, C,
D, E, F
V12
R1, V15
V11 R3 R2 See Section

Optional 9-3 for waveforms
Glow Plug Throttle Solenoid
TS1 A, B, C, D, E, F
Relay CR2 (Pull to weld)

Resistance Values
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold
machine (no warm-up) Voltage Readings
c) Wiring Diagram − see Section 11 a) Tolerance − ±10% unless specified
d) Stop engine before checking b) Condition − 70°F (21°C); cold machine
resistance (no warm-up); no load
R1 Less than 1 ohm (extended) c) Reference − single arrow: reference to
10 − 12 ohms (retracted) circuit common (lead 33); double
R2 50.7 ohms arrow: reference to points indicated
R3 1 ohm d) Wiring Diagram − see Section 11
R4 3.6 ohms
R5 thru R10 Less than 1 ohm V1 AC/CC OCV at weld/power rpm:
65 volts ac (R1 at min.)
80 volts ac (R1 at max.)
Amperage Readings
V2 DC/CC OCV at weld/power rpm:
a) Tolerance − ±5% unless specified 58 volts dc (R1 at min.)
72 volts dc (R1 at max.)
b) Condition − 70°F (21°C); cold
V3 DC/CV OCV at weld/power rpm:
machine (no warm-up); no load 25 volts dc (R1 at min.)
I1 3 amps dc (R1 at min.) 32 volts dc (R1 at max.)
7.3 amps dc (R1 at max.) V4 At RC2 at weld/power rpm:
132 volts ac ±5% (R1 at max.)
Do not exceed 132 volts ac.
V5 At RC1 at weld/power rpm:
Do not exceed 264 volts ac.
V6 DC output to revolving field:
6.5 − 10.5 volts dc (idle rpm)
13 − 29.5 volts dc (weld/power rpm)
V7 43 − 50 volts ac
V8 No weld load: 0 volts ac
Rated dc weld load: 3.5 volts ac or greater
V9 No power load: 0 volts ac
15 ampere power load: 3.5 volts ac or
greater
V10 At weld/power rpm and 100 watt light bulb
load applied: 1 volt ac ±20%
V11 AC input to regulator:
29 volts ac (idle rpm)
46 volts ac (weld/power rpm)
V12 DC output from regulator (from center
terminal on regulator to ground):
14 volts dc ±5% at idle or weld/power rpm
V13 No weld or power load and S2 in Run
position: 10 volts dc
V14 No weld or power load and S2 in Run/Idle
position: 12 − 14.5 volts dc
V15 No load and S2 in Run/Idle position:
0 volts dc; No load and S2 in Run position:
12 − 14 volts dc
V16 At weld/power rpm with Lynx Plasma Cutter
connected to RC40:
V17 With engine running and Lynx Plasma Cutter
connected to RC40: 14 volts dc ±5%
Ref. 182 630-B

9-3. Waveforms For Section 9-2
2 ms 50 V 2 ms 10 V
gnd gnd
A. DC/CC Open-Circuit Voltage, Fine Adjust B. DC/CC Output, 25 Volts, 100 Amperes
Control R1 At Maximum (Resistive Load), Coarse Adjust Switch S3
At 70−150 Position
2 ms 20 V 2 ms 10 V
gnd gnd
C. DC/CV Open-Circuit Voltage, Fine Adjust D. DC/CV Output, 25 Volts, 100 Amperes
Control R1 At Maximum (Resistive Load)

5 ms 50 V 5 ms 20 V
gnd gnd
E. AC/CC Open-Circuit Voltage, Fine Adjust F. AC/CC Output, 25 Volts, 100 Amperes
Control R1 At Maximum (Resistive Load)
5 ms 50 V 5 ms 200 V
gnd gnd
G. AC Open-Circuit Voltage At 120 Volt H. AC Open-Circuit Voltage At 240 Volt

Receptacle RC2, Fine Adjust Control R1 At Receptacle RC1, Fine Adjust Control R1 At
Maximum Maximum

NOTE Effective with Serial No. KK327894, the one-piece stator barrel was replaced by a
two-piece housing. Most views in this manual were revised to reflect this change.
9-4. Idle Module PC1 Testing Information

Be sure plugs are secure before
testing. See Section 9-5 for specific
values during testing.
1 Idle Module PC1
Prior To KJ029173 1 Eff. w/ KJ029173 1
D C
G E
B F
A
Ref. 801 521-C / Ref. 142 725

9-5. Troubleshooting Flowcharts For Idle Module PC1
Y Stop engine before connecting or changing

meter leads and before replacing any parts.
Engine does not go to idle speed Engine does not go to weld/power

(2200 rpm) with no load applied. speed (3750 rpm) with load applied.
Connect meter (DC) between Connect meter (DC) between

terminal B (+) and terminal E (−). terminal B (+) and terminal E (−).
Start engine, and place Engine Start engine, and place Engine
Control switch and Idle Lock Control switch and Idle Lock
switches in Run/Idle position. switches in Run/Idle position.
Check connections Check connections

NO to Engine Control NO to Engine Control
+12 volts dc present? switch S2 and +12 volts dc present? switch S2 and
ground connection ground connection
(lead 33). (lead 33).
YES YES
Connect meter (AC) between Connect meter (AC) between

terminal G and terminal E. terminal G and terminal E.
Check for internal

NO
load such as Connect a 100 watt light bulb to
0 (zero) volts ac present?
shorted diode in 120 volts ac duplex receptacle.
main rectifier SR1.
YES
Connect meter (DC) between NO Check connections

terminal C (+) and terminal E (−). Minimum of 1 volt ac present? to current
transformer CT1.
YES
NO
0 (zero) volts dc present? Replace idle Connect meter (DC) between
module PC1. terminal C (+) and terminal E (−).
YES
NO
Check throttle linkage for smooth Approximately +10 volts dc Replace idle
non-binding operation. present? module PC1.
YES
Check relay CR1, and check

Reinstall cover. throttle linkage for smooth,
non-binding operation.
Disconnect 100 watt light bulb

and meter leads.
Reinstall cover.

9-6. Replacing Brushes And Cleaning Slip Rings Prior To Serial No. KH356820
1 Endbell
2 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
3 Brush Holder
4 Brush With Spring
5 Brush Holder Cap
Mark and disconnect leads at caps,
and remove brushes from bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Y Stop engine.
Install brushes, bracket, and
remaining generator parts (see
Section 10-2 for torque values).
Reinstall side panels and cover.
2
3
4
5
5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)

New Length
Tools Needed:
Replace 5/32 in
Damaged Brushes
1/4, 3/8, 1/2 in
Ref. 801 521-A / 801 879 / S-0233-A

9-7. Replacing Brushes And Cleaning Slip Rings Effective With Serial No. KH356820
Thru KK327893
1 Endbell
2 Brushes
3 Brush Holder Assembly
Remove brush holder assembly.
Do not remove brushes from hol-
der. Replace brush holder assem-
bly if brushes are damaged, or at or
near minimum length.
4 Slip Rings
start engine and clean rings with a
Y Stop engine.
Install brush holder assembly and
2
3
1/4 in (6.4 mm)

Minimum Length
1/2 in (12.7 mm)

New Length
Replace
Damaged Brushes
Tools Needed:
5/32 in
1/4, 3/8, 1/2 in
Ref. 801 521-B / Ref. 166 866-C / Ref. 166 867-B / S-0233-A

9-8. Replacing Brushes And Cleaning Slip Rings Effective With Serial No. KK237894
1 Endbell
2 Brushes
3 Brush Holder Assembly
Remove brush holder assembly.
Do not remove brushes from hol-
der. Replace brush holder assem-
bly if brushes are damaged, or at or
near minimum length.
4 Slip Rings
start engine and clean rings with a
Y Stop engine.
Install brush holder assembly and
2
3
1/4 in (6.4 mm)

Minimum Length
1/2 in (12.7 mm)

New Length
Replace
Damaged Brushes
Tools Needed:
5/32 in
1/4, 3/8, 1/2 in
Ref. 801 521-C / Ref. 166 866-C / Ref. 166 867-B / S-0233-A

9-9. Checking Unit Output After Servicing
. Effective with Serial No.

KH426280, resistor R2 is not
adjustable. Unit output can no
longer be changed by adjusting
R2.
Check engine speeds, and adjust if
necessary (see Section 7-5).
Set Fine Adjust control at 10.
Prior to Serial No. 1 Weld Output Terminals
KH426280 only.
Check open-circuit voltages be-
tween terminals (see Section 9-2,
2 voltages V1, V2 and V3).
3
If correct voltages are not present,
proceed as follows:
Models prior to Serial No.
KH426280 only:
2 Resistor R2
3 Slider
Y Stop engine before adjusting
resistor R2.
Adjust slider on R2 until open-
circuit voltages are okay. Do not ex-
ceed maximum amperage in re-
volving field (see Section 9-2,
Amperage I1).
All models:
Run engine at weld/power speed
(3750 rpm).
Receptacles RC2 And RC3
Check voltage at each receptacle.
With no load applied, there should
be 125 − 132 volts ac present.
5 240 V 50 A AC Receptacle
5 RC1
Check voltage at receptacle. With
no load applied, there should be
258 − 264 volts ac present.
If correct voltages are not present,
1 repeat troubleshooting procedures
in Section 9-1.
Y Stop engine.
Allow engine to cool, and then com-
4 plete pre-operational checks in
table.
Reinstall cover and side panels.
Pre-Operational Checks
Wipe engine surfaces clean.

Tools Needed:
Check labels; replace labels that are unreadable or damaged (see Parts List).
Check fuel and oil.
3/8 in
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Ref. 801 521-C / Ref. 154 094-A

SECTION 10 − DISASSEMBLY AND REASSEMBLY
10-1. Disassembly Of Unit Prior To Serial No. KK327894
Disassembly:
Use Section 9 to determine if
trouble is in rotor, stator, or a com-
bination of these parts.
Tools Needed: Y Do not damage rotor or
stator windings.
Disconnect battery cables, fuel line,
plug PLG4, throttle solenoid cable,
5/32 in and base ground cable.
Mark and disconnect stator leads
and leads to resistor R2.
Disassemble in sequence shown.
Y Use hoist and lifting strap to
remove engine/generator as-
sembly.
To Remove Rotor:
1 Rotor Removal Tool
(Customer Supplied)
2 Screw, 1/2-13 x 1-1/2
(Customer Supplied)
Make rotor removal tool from steel
rod according to specifications.
Slide narrow end of tool through ro-
tor into engine shaft. Turn screw
into rotor while lightly tapping rotor
laminations. (Turning screw into ro-
tor forces rotor off engine shaft.)
Reassembly:
Reassemble unit in reverse order of
disassembly.
Torque hardware as specified in
Section 10-2.
Reconnect resistor R2 and stator
leads according to circuit diagram.
Use cable ties to keep leads from
hot or moving parts.
Reconnect fuel line, solenoid cable,
plug PLG4, and base ground cable.
Reinstall panels, and cover. Recon-
nect battery cables.
1
2
Apply SAE 30W oil to stator studs be-
fore installing in engine adapter.
Use double-nut method 15-3/4 in 1-7/16 in

(400 mm) (36.5 mm)
to remove rotor stud.
5/16 in 1/4 in
(8 mm) (6.35 mm)
801 522-B

10-2. Disassembly Of Generator Prior To Serial No. KK327894
Torques:
Prior To KH356820 Eff. w/KH356820

Thru KK327893
A 60 in lb (7 N.m) A 25 in lb (3 N.m)
B 16 ft lb (21.7N.m) 6
B
C 10 ft lb (14 N.m)
5
4
Models Effective With Serial No.
3
KH356820 Thru KK
2
1
Apply SAE 30W oil to stator studs be-

7 fore installing in engine adapter.
11
10 8
A Models Prior To Serial No. KH356820

C
12
13
14
15
16
C
A
Y Do not damage rotor or 5 Rotor Stud 11 Endbell

stator windings. 6 Engine Adapter 12 Brush Holder Bracket
1 Bearing 7 Stator Stud 13 Brush Holder
2 Slip Rings 8 Stator 14 Brush With Spring
3 Rotor 9 Brush Holder Assembly 15 Brush Holder Cap
4 Generator Fan 10 O-Ring 16 Brush Holder Bar
173 092-A

10-3. Disassembly Of Unit Effective With Serial No. KK327894
Disassembly:
Use Section 9 to determine if
trouble is in rotor, stator, or a com-
bination of these parts.
Tools Needed: Y Do not damage rotor or
stator windings.
Disconnect battery cables, fuel line,
plug PLG4, throttle solenoid cable,
5/32 in and base ground cable.
Mark and disconnect stator leads
and leads to resistor R2.
Disassemble in sequence shown.
Y Use hoist and lifting strap to
remove engine/generator as-
sembly.
To Remove Rotor:
1 Rotor Removal Tool
(Customer Supplied)
2 Screw, 1/2-13 x 1-1/2 (Cus-
tomer Supplied)
Make rotor removal tool from steel
rod according to specifications.
Slide narrow end of tool through ro-
tor into engine shaft. Turn screw
into rotor while lightly tapping rotor
laminations. (Turning screw into ro-
tor forces rotor off engine shaft.)
Reassembly:
Reassemble unit in reverse order of
disassembly.
Torque hardware as specified in
Section 10-4.
Reconnect resistor R2 and stator
leads according to circuit diagram.
Use cable ties to keep leads from
hot or moving parts.
Reconnect fuel line, solenoid cable,
plug PLG4, and base ground cable.
Reinstall panels, and cover. Recon-
nect battery cables.
1
2
Use double-nut method

to remove rotor stud.
15-3/4 in 1-7/16 in
(400 mm) (36.5 mm)
5/16 in 1/4 in
(8 mm) (6.35 mm)
801 522-C

10-4. Disassembly Of Generator Effective With Serial No. KK327894
Torques:
A 12 ft lb (16 N.m)
B 16 ft lb (21.7 N.m)
C 35 ft lb (47 N.m)
D 25 in lb (3 N.m)
A 4
B
Route stator leads
through this opening.
3
B
7
2 8
9
10
11
D
C
173 092-D
Y Do not damage rotor or 4 Rotor Stud 8 Rotor

stator windings.
5 Engine Adapter 9 Slip Rings
1 O-Ring
2 Front Generator Housing 6 Rear Generator Housing 10 Bearing
3 Stator Windings 7 Generator Fan 11 Brush Holder Assembly

Notes

SECTION 11 − ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for actual circuit, if needed.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Bobcat 225D Plus KG076022 thru KG196039 SC-172 137-D D-172 700-D♦♦
KG196040 and following SC-182 630-B SD-182 631-C
♦♦ Not included in this manual

SD-172 137-D
Figure 11-1. Circuit Diagram For Bobcat 225D Plus Effective With Serial No. KG076022 Thru KG196039
SC-182 630-B
Figure 11-2. Circuit Diagram For Bobcat 225D Plus Effective With Serial No. KG196040 And Following
Figure 11-3. Wiring Diagram For Bobcat 225D Plus Effective With Serial No. KG196040 And Following
Coat terminals with conductive electric compound (Miller
Part No. 603 978) or equivalent.
Coat terminals with dielectric grade, nonconductive, elec-

tric grease (MILLER Part No. 146 557) or equivalent.
SD-182 631-C

SECTION 12 − RUN-IN PROCEDURE
run_in1 8/01
12-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
. Do not idle engine longer than

necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
1 run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
OM-404 Page 50 Bobcat 225D Plus

12-2. Run-In Procedure Using Load Bank
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
4
from flammables.
2 procedure at less than 20
1 exceed duty cycle or equip-
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
minutes.
3 Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
. Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Repeat procedure if wetstacking is
present.
S-0683
Bobcat 225D Plus OM-404 Page 51

12-3. Run-In Procedure Using Resistance Grid
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
6
from flammables.
2 procedure at less than 20
exceed duty cycle or equip-
1 Resistance Grid
Use grid sized for generator rated
output.
1 Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3 5 Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rat-
4 ing label, or the specifications sec-
tion in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
+ loaded properly.
. Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Repeat procedure if wetstacking is
present.
S-0684
OM-404 Page 52 Bobcat 225D Plus

TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/KG076022 Thru KH559130

For OM-404 (175 611) Revisions * Thru C

www.MillerWelds.com
SECTION 13 − PARTS LIST FOR KG076022 THRU KH559130
30
29
25
26
. Hardware is common and
31
32
not available unless listed.
33
27
34
28
40
41
39
24
42
38
35
Fig13-3
43
36
37
23
45
44
22
49
50
21
47
48
20
19
46
44
18
17
16
15
14
57
56
13
12
55
11
9
10
51
8
54
58
52
53
7
60
61
59
6
62
3
70
2
63
69
68
67
71
66
65
1
Fig 13-2
64
ST-801 516−B
Figure 13-1. Main Assembly
Item Dia. Part
No. Mkgs. No. Description Quantity
. . . 1 . . . . . . . . . . . . . . . . . . 134 792 . . . LABEL, warning general precautionary (Eff w/KG196519) . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . +159 907 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . +♦169 441 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 108 487 . . . LABEL, warning falling equipment can cause serious injury . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . . . . 159 914 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . 160 975 . . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . . . 168 640 . . . SEAL, tank fuel filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . 164 928 . . . SEAL, barrel 11.78 ID x .378thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 172 663 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . 147 601 . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . 172 657 . . . TANK, fuel 8.5gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . 178 632 . . . . FITTING, stand pipe hose .250 x 7.325 lg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . 172 742 . . . CLAMP, hose .240-.300clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, return line (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 107 816 . . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . 1ft
. . . 17 . . . . . . . . . . . . . . . . . . 066 113 . . . FILTER, fuel in-line .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . 165 437 . . . CLIP, snap-in .472 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . . . . . 141 975 . . . WASHER, flat copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . 177 123 . . . SWITCH, pressure oil 4PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . 142 118 . . . FITTING, pipe brs adapter 1/8NPT x 8m−1−6G . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . +172 635 . . . ENGINE, diesel elec start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . 142 322 . . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, fuel filter (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . . . . 066 893 . . . ELEMENT, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . 165 271 . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . 172 634 . . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . . . . 149 610 . . . STOP, cable throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . 150 203 . . . SPRING, cprsn .372 OD x .051 wire x 1.500 . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . 172 668 . . . CONTROL, push/pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . TS1 . . . . . . 149 618 . . . SOLENOID, 12VDC 44A (Prior to KG196519) . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . TS1 . . . . . . 179 385 . . . SOLENOID, 12VDC 46A (Eff w/KG196519) . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . 174 803 . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . . . Fig 13-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . 087 318 . . . CLAMP, stl cush 1.000dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . . . . . 176 890 . . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . 168 385 . . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . +159 917 . . . DOOR, access battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos (included w/engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . 108 081 . . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . 2
. . . 43 . . . . . . . . . . . . . . . . . . 167 677 . . . BATTERY, stor 12V 430crk 75rsv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . . . . 165 630 . . . BOLT, J stl .250-20 x 6.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . . . . . . 172 720 . . . BRACKET, mtg engine upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . . . . 166 094 . . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 48 . . . . . . . . . . . . . . . . . . 172 719 . . . BRACKET, mtg engine lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . . . . 159 906 . . . PAN, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . . . . . 173 094 . . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . . . . . 160 844 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 52 . . . . . . DC-Z . . . . . . 165 578 . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . 164 920 . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . 54 . . . . . . AC-Z . . . . . . 176 301 . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . . . . . . 172 715 . . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . . . . 172 714 . . . BRACKET, mtg engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . . . . 172 707 . . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . . . . . 172 625 . . . BRACKET, mtg rectifier/components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . 1T . . . . . . . 172 661 . . . BLOCK, stud connection 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 62 . . . . . . . SR1 . . . . . . 142 503 . . . RECTIFIER, si 1 ph 300A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . +159 911 . . . PANEL, front lower (Prior to KG196519) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . . 180 628 . . . PANEL, front lower (Eff w/KG196519) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 761 . . . LABEL, warning general precautionary (Prior to KG196519) . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . . . . Fig 13-2 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . CT1 . . . . . . 179 494 . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . 177 136 . . . CLAMP, capacitor 2.500dia clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . C1 . . . . . . . 176 719 . . . CAPACITOR, elctlt 1000uf 75VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . . . . 172 731 . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . SR2,3 . . . . . 035 704 . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . R2 . . . . . . . 184 278 . . . RESISTOR, WW adj 225W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . RC4 . . . . . . 116 045 . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . PLG6 . . . . . 136 810 . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . PLG4 . . . . . 135 556 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . RC6 . . . . . . 168 844 . . . CONNECTOR, rect 4 pin/skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 612 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Part of optional 043 051 Stainless Steel Kit

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Item Dia. Part

Figure 13-2. Panel, Front w/Components (Fig 13-1 Item 64)
. . . 1 . . . . . . . S1 . . . . . . . 184 754 . . . SWITCH, polarity 5 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . 172 787 . . . NAMEPLATE, (Prior to KH340290) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . 185 184 . . . NAMEPLATE, (Eff w/KH340290) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 165 602 . . . PANEL, front (Prior to KH340290) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 183 171 . . . PANEL, front (Eff w/KH340290) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . S3 . . . . . . . 183 148 . . . SWITCH, selector 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . R1 . . . . . . . 205 839 . . . RHEOSTAT, WW 100W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . PC1 . . . . . . 142 725 . . . MODULE, weld/power 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . CR1 . . . . . . 173 069 . . . RELAY, encl 12VDC SPDT 15A 125VDC . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . S2 . . . . . . . 176 606 . . . SWITCH, ignition 4 position w/out handle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . RC2,3 . . . . . 167 657 . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . GFCI2,3 . . ♦147 939 . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . CB1,2 . . . . . 117 501 . . . CIRCUIT BREAKER, man reset 1P 40A 250VAC . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . CB3,4 . . . ♦093 995 . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . S5 . . . . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 021 385 . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . CB8 . . . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250VDC . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

(Continued)
... 15 .................. 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 16 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . Work, Elect . . . 099 255 . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 . . . . . . RC1 . . . . . . 164 704 . . . RECEPTACLE, str 3P4W 50A 125/250V (Prior to KH340290) . . . . . 1
... 18 . . . . . . RC1 . . . . . . 182 954 . . . RECEPTACLE, str 3P4W 50A 125/250V (Eff w/KH340290) . . . . . . . 1
... 19 .................. 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 .................. 010 915 . . . WASHER, flat .250 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 21 .................. 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 22 .................. 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 .................. 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 24 .................. 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 2 3 4 5
6
7
10
11
12
13
24
23
14
19 16 15
20
21
22
18
17
17
ST-801 517
Figure 13-2. Panel, Front w/Components
♦OPTIONAL
Item Part
No. No. Description Quantity
Figure 13-3. Generator (Fig 13-1 Item 35)
. . . 1 . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . 165 818 . . LABEL, warning engine fuel can cause fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . +172 652 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . 179 885 . . ROTOR, generator (Prior to KH356820) (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . 053 390 . . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . 160 566 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . 184 612 . . ROTOR, generator (Eff w/KH356820) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . 160 566 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . 179 647 . . STUD, stl .312-18 x 18.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . 172 665 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . 160 573 . . STUD, stl .375-16 x 17.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . 125 548 . . HOLDER, brush elect (Prior to KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . 005 614 . . HOLDER, brush (Prior to KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . *126 984 . . BRUSH w/SPRING (Prior to KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . 161 306 . . CAP, brushholder (Prior to KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . 047 879 . . BAR, retaining brushholder (Prior to KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . 180 556 . . HOLDER, brush elect (Eff w/KH356820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . 010 910 . . WASHER, flat .406 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 16 . . . . . . 010 909 . . NUT, .375-16 stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . 160 943 . . ENDBELL, (Prior to KH356820) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . 183 422 . . ENDBELL, (Eff w/KH356820) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . 183 419 . . . . O-RING, 1.094 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. Hardware is common and 7

Models Effective With Serial No. KH356820

5
3
4
2
1
8
9
10
11
12
13
17 18
14
Models Prior To Serial No. KH356820
15
16 ST-173 092-A
Figure 13-3. Generator

TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/KH559131 Thru KJ274741

For OM-404 (175 611) Revisions D Thru G

www.MillerWelds.com
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23
25
22
TM-404 Page 60
20 21
15 17 19
14 16
4 11
10 18 26
8 13
12 27 28
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5 7
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30
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31
70 32
36 33
35 − Fig. 14-3
64 68 69 56
67
39 40
66
65 55
58 54 38
53 37
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60 51
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Fig 14-2 − 63
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48 43
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45
46
SECTION 14 − PARTS LIST FOR KH559131 THRU KJ274741
Bobcat 225D Plus

ST-801 516-E
Item Dia. Part
. . . 1 . . . . . . . . . . . . . . . . . . 134 792 . . . LABEL, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . +159 907 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . ♦+169 441 . . . COVER, top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . . 159 914 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . . . 168 640 . . . SEAL, tank fuel filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 172 663 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . 172 657 . . . TANK, fuel 8.5gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . 178 632 . . . . FITTING, stand pipe hose .250 x 7.325 lg . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, return line (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . 107 816 . . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . 1ft
. . . 30 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . TS1 . . . . . . 179 385 . . . SOLENOID, 12VDC 44A pull/hold w/o spring . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . Fig 14-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . 182 935 . . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . 186 896 . . . BRACKET, battery tray support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . 201 280 . . . BASE, pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 47 . . . . . . DC-Z . . . . . . 165 578 . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . . . . 164 920 . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 49 . . . . . . AC-Z . . . . . . 176 301 . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . . . . . 186 741 . . . SPACER, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . 172 714 . . . BRACKET, engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

. . . 60 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . . . . 180 628 . . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 612 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
Item Dia. Part

. . . 1 . . . . . . . S1 . . . . . . . 184 754 . . . SWITCH, polarity 5 position (Weld Process) . . . . . . . . . . . . . . . . . . . . 1

... 2 ............................. NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 183 171 . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . COVER, dust (Eff w/KJ076171) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . S3 . . . . . . . 183 148 . . . SWITCH, selector 4 position (Coarse Adjustment) . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . R1 . . . . . . . 205 839 . . . RHEOSTAT, WW 100W 10 ohm (Fine Adjustment) . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . PC1 . . . . . . 142 725 . . . MODULE, weld/power 7 pin (Prior to KJ029173) . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . PC1 . . . . . . 186 224 . . . MODULE, weld/power 7 pin (Eff w/KJ029173) . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . S2 . . . . . . . 176 606 . . . SWITCH, ignition 4 position w/out handle (Engine) . . . . . . . . . . . . . . . 1
. . . 10 . . . . . GFCI2,3 . . ♦147 939 . . . RECEPTACLE, str dx grd 2P3W 15A . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . CB3,4 . . . ♦093 995 . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . S5 . . . . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VDC (Idle Lock) . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

(Continued)
. . . 17 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . Work, Elect . . . 099 255 . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . . . . 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . 010 915 . . . WASHER, flat .250 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 21 . . . . . . . . . . . . . . . . . . 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . . . . . . . . . . . . . . . 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . . 147 195 . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 24 . . . . . . RC1 . . . . . . 182 954 . . . RECEPTACLE, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . 1
........................ 119 172 . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

not available unless listed. 1
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ST-801 517-B
♦OPTIONAL
Item Part
. . . . . . . . . . . . 165 818 . . LABEL, warning engine fuel can cause fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . +188 444 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . 184 612 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . 160 566 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . 179 647 . . STUD, stl .312-18 x 18.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . 172 665 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . 160 573 . . STUD, stl .375-16 x 17.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . 180 556 . . HOLDER, brush elec
. . . 10 . . . . . . 010 910 . . WASHER, flat .406 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 11 . . . . . . 010 909 . . NUT, .375-16 stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . 183 422 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . 183 419 . . . . O-RING, 1.094 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5
3
4
2
1
8
12 13
9
ST-173 092-B
10
11

TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/KJ274742 Thru KK327893

For OM-404 (175 611) Revision H

www.MillerWelds.com
3
2 4
5 20
1
19
TM-404 Page 66
21
18
16 17
15
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14 22
10 13
23 24
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31−Fig.15-3
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48 33
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54 47

37
46
55
Fig 15-2 − 57
44 45
38
43 39
56
40
41
SECTION 15 − PARTS LIST FOR KJ274742 THRU KK327893
42
ST-801 516-F
Bobcat 225D Plus

Item Dia. Part
. . . 1 . . . . . . . . . . . . . . . . . . 192 041 . . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . 181 881 . . . GROMMET, filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . +191 276 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . ♦+191 988 . . . COVER, top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . 159 914 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 190 825 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . 191 427 . . . TANK, fuel 10 gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 187 502 . . . . FITTING, stand pipe hose .250 x 7.325 lg 90° . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 922 . . . . BUSHING, tank fuel 1.210 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, return line (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 107 816 . . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . 1ft
. . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . Fig 15-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 No. 4 AWG w/clamp . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.00 No. 6 AWG w/.250 & .375 ring terminals . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . 201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 43 . . . . . . . . . . . . . . . . . . 183 771 . . . STAB/REACTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 164 920 . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Item Dia. Part

. . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . SR1 . . . . . . 142 503 . . . RECTIFIER, si 1 ph 300A 400PIV (Prior to KK015994) . . . . . . . . . . . 1
. . . 55 . . . . . . . SR1 . . . . . . 192 682 . . . RECTIFIER, si 1 ph 240A 400PIV (Eff w/KK015994) . . . . . . . . . . . . . 1
. . . 62 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 612 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
Item Dia. Part


. . . 3 . . . . . . . . . . . . . . . . . . 183 171 . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

(Continued)

. . . 19 . . . . . . . . . . . . . . . . . . 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . . . . . . . . . . . . . . . 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . . 147 195 . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
........................ 119 172 . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5
6
2 3 4
7
10
11
12
13
14
26
25
15
24
23
19 16
17
20
21
22
18
18
ST-801 517-C
♦OPTIONAL

Item Part
... 1 . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . . +188 444 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . 184 612 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . 181 143 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . 160 566 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . 179 647 . . STUD, stl .312-18 x 18.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . 172 665 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . 160 573 . . STUD, stl .375-16 x 17.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 9 . . . . . . 180 556 . . HOLDER, brush elec
... 10 . . . . . . 010 910 . . WASHER, flat .406 ID stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 11 . . . . . . 010 909 . . NUT, .375-16 stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 12 . . . . . . 183 422 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . 183 419 . . . . O-RING, 1.094 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5
3
4
2
1
8
12 13
9
ST-173 092-B
10
11

TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/KK327894 Thru LA236778

For OM-404 (175 611) Revisions J And K

www.MillerWelds.com
SECTION 16 − PARTS LIST FOR KK327894 THRU LA236778
Fig 16-3
66
Fig 16-2 − 57
ST-801 516-G

Item Dia. Part

. . . 5 . . . . . . . . . . . . . . . . . +191 276 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . ♦+191 988 . . . COVER, top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . 186 670 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 194 253 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . Fig 16-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 No. 4 AWG w/clamp . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.00 No. 6 AWG w/.250 & .375 ring terminals . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . +201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

. . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 612 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . 197 930 . . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 67 . . . . . . . . . . . . . . . . . . 079 624 . . . SCREW, .375-16 x 2.25 hex hed pln stl pld full thlkg pa . . . . . . . . . . 1
♦OPTIONAL
Item Dia. Part

. . . 3 . . . . . . . . . . . . . . . . . . 183 171 . . . PANEL, front (Prior to LA077341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 198 910 . . . PANEL, front (Eff w/LA077341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦183 171 . . . PANEL, front w/battery charger option (Eff w/LA077341) . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦185 161 . . . PANEL, front w/Aus./South African rec. option (Eff w/LA077341) . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 16-2. Panel, Front w/Components (Fig 16-1 Item 57) (Continued)
. . . 17 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . . . . . 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . . . . . . . . . . . . . . . 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . . 147 195 . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
........................ 119 172 . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5
6
2 3 4
7
10
11
12
13
14
26
25
15
24
23
19 16
17
20
21
22
18
18
ST-801 517-C
♦OPTIONAL
Item Part
. . . 1 . . . . . +196 898 . . HOUSING, generator front assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . 079 624 . . . . SCREW, 375−16x2.25 hex hd−pln stl pld full thlkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . 183 419 . . . . O−RING, 1.984 id x .139 cs 70 duro viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . 179 508 . . STATOR, weld/pwr exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . 195 956 . . SCREW, .250-20 x 5.75 hexwhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 6 . . . . . . 179 647 . . STUD, stl .312-18 x 18.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . 189 974 . . ADAPTER, housing generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . 178 527 . . HOUSING, generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . 174 828 . . SCREW, M 8−1.2X 45 hex hd−pln 8.8 pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 10 . . . . . . 189 743 . . ROTOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . 181 134 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . 181 143 . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . 180 556 . . HOLDER, brush elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . 142 156 . . SCREW, .375-16 x 1.75 hexwhd .81d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7
6
5
4
3
9
11
1
12 10
13
14
Ref. 173 092-D


TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/LA236779 Thru LB064992

For OM-404 (175 611) Revisions L Thru N

www.MillerWelds.com
SECTION 17 − PARTS LIST FOR LA236779 THRU LB064992
65
ST-801 516-H

Item Dia. Part

. . . 4 . . . . . . . . . . . . . . . . . . 200 795 . . . LABEL,warning gen. precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . +191 276 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . ♦+191 988 . . . COVER, top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . 186 670 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 194 253 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . Figure 17-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 (battery to engine block) . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.000 (engine block to case) . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . +201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

. . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . . Figure 17-2 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 182 612 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
Item Dia. Part

Figure 17-2. Panel, Front w/Components (Figure 17-1 Item 57)

. . . 3 . . . . . . . . . . . . . . . . . . 198 910 . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦183 171 . . . PANEL, front (w/battery charger option) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦185 161 . . . PANEL, front (w/Australian or South African receptacle option) . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . GFCI2,3 . . ♦151 981 . . . RECEPTACLE, str dx grd 2P3W 15/20A 125VAC GFI . . . . . . . . . . . 2
. . . 15 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 17-2. Panel, Front w/Components (Figure 17-1 Item 57) (Continued)
. . . 17 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . . . . . 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . . . . . . . . . . . . . . . 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . . 147 195 . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
........................ 119 172 . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . 200 532 . . . LABEL, warning CSA circuit breaker (Eff w/LA290540) . . . . . . . . . . . 1

5
6
2 3 4
7
10
11
12
13
14
26
25 27
15
24
23
19 16
17
20
21
22
18
18
ST-801 517-C
♦OPTIONAL
Item Part
Figure 17-3. Generator (Figure 17-1 Item 31)
... 1 . . . . . +194 620 . . HOUSING, generator front assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . 183 419 . . . . O−RING, 1.984 id x .139 cs 70 duro viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . 167 632 . . . . SCREW, 375−16x1.50 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . 179 508 . . STATOR, weld/pwr exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . 195 956 . . SCREW, .250-20 x 5.75 hexwhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 7 . . . . . . 179 647 . . STUD, stl .312−18+24 x 18.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . 189 974 . . ADAPTER, housing generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . 178 527 . . HOUSING, generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . 174 828 . . SCREW, M 8−1.2X 45 hex hd−pln 8.8 pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . . . . . 189 743 . . ROTOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . 181 134 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . 181 143 . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . 180 556 . . HOLDER, brush elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . 142 156 . . SCREW, .375-16 x 1.75 hexwhd .81d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8
7
6
5
4
10
12
1
13 11
2
3
14
15
Ref. 173 092-F

TM-404H July 2004
Processes
MIG (GMAW) Welding


Welding
Description
Bobcat 225D

Eff w/LB064993 And Following

For OM-404 (175 611) Revisions P thru T

www.MillerWelds.com
SECTION 18 − PARTS LIST FOR LB064993 AND FOLLOWING
65
ST-801 516-H

Item Dia. Part

. . . 4 . . . . . . . . . . . . . . . . . . 200 795 . . . LABEL,warning gen. precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . +191 276 . . . COVER, top (Prior to LC116933) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . +205 763 . . . COVER, top (Eff w/LC116933) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . ♦+191 988 . . . COVER, top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . . ♦169 442 . . . PANEL, side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . 186 670 . . . UPRIGHT, base (Prior to LC116933) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . . . 205 736 . . . UPRIGHT, base (Eff w/LC116933) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . 160 975 . . . SEAL, weather lift eye (Prior to LC116933) . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . 205 734 . . . SEAL, weather lift eye (Eff w/LC116933) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . 194 253 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . Figure 18-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 (battery to engine block) . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.000 (engine block to case) . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . +182 897 . . . DOOR, access battery (Prior To LB150446) . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . +201 174 . . . DOOR, access battery (Eff w/LB150446) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . +201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Item Dia. Part
. . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . SR1 . . . . . . 192 682 . . . RECTIFIER, si 1 ph 240A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . . Figure 18-2 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . F1 . . . . . . *169 296 . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 207 503 . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
Item Dia. Part

. . . 3 . . . . . . . . . . . . . . . . . . 198 910 . . . PANEL, front (Prior to LC144075) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . 207 845 . . . PANEL, front (Eff w/LC144075) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦183 171 . . . PANEL, front (w/battery charger option) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦185 161 . . . PANEL, front (w/Australian or South African receptacle option) . . . . 1
. . . 3 . . . . . . . . . . . . . . . . ♦203 681 . . . PANEL, front (w/CSA receptacle option) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . GFCI2,3 . . ♦151 981 . . . RECEPTACLE, str dx grd 2P3W 15/20A 125VAC GFI . . . . . . . . . . . 2
. . . 11 . . . . . . . CB1 . . . . ♦200 929 . . . CIRCUIT BREAKER, man reset 2p 50a 240vac screw−90 (CSA) . . 1
. . . . . . . . . . . . . . . . . . . . . . ♦202 631 . . . COVER, circuit breaker (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . ♦202 630 . . . BRKT, mtg ckt breaker cover (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part

(Continued)
. . . 15 . . . . . . . HM . . . . . . 145 247 . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . R3,VR1 . . . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . 083 030 . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . 601 836 . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . . . . . . . . . . . . . . . 159 921 . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . . . 147 195 . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . 119 172 . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . 148 956 . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . 200 532 . . . LABEL, warning CSA circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5
6
2 3 4
7
10
11
12
13
14
26
25 27
15
24
23
19 16
17
20
21
22
18
18
ST-801 517-C
♦OPTIONAL
Item Part
Figure 18-3. Generator (Figure 18-1 Item 31)
... 1 . . . . . +194 620 . . HOUSING, generator front assy (Prior to LB207095) (consisting of) . . . . . . . . . . . 1
... 1 . . . . . +205 901 . . HOUSING, generator front assy (Eff w/LB207095) (consisting of) . . . . . . . . . . . . . 1
... 2 . . . . . . 183 419 . . . . O−RING, 1.984 id x .139 cs 70 duro viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . 079 624 . . . . SCREW, .375−16 x 2.25 hex hd−pln stl pld full thlkg pa . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . 179 647 . . STUD, stl .312−18+24 x 18.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . 189 974 . . ADAPTER, housing generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . 178 527 . . HOUSING, generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . 174 828 . . SCREW, M 8−1.2X 45 hex hd−pln 8.8 pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 9 . . . . . . 189 743 . . ROTOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . 181 134 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . 181 143 . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . 180 556 . . HOLDER, brush elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . 142 156 . . SCREW, .375-16 x 1.75 hexwhd .81d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 10
11 9
12
13
3 Ref. 173 092-G

Notes
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA  2003 Miller Electric Mfg. Co.

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Bobcat225D Plus

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TM-404H July 2004

Eff. w/Serial Number KG076022

MIG (GMAW) Welding

Non-Critical TIG (GTAW)

Engine Driven Welding Generator

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1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.

MOVING PARTS can cause injury.

Bobcat 225D Plus TM-404 Page 1

1-3. EMF Information

TM-404 Page 2 Bobcat 225D Plus

2-1. Symbol Definitions

Start Engine Glow Plug Temperature Fuel

Check Injectors/ Check Valve

Gas Metal Arc Shielded Metal Arc Gas Tungsten Arc

Do not switch while Welding Arc

210 A, 25 V, Continuous: 8 kVA/kW, Deutz/Ruggerini MD-151

Bobcat 225D Plus TM-404 Page 3

C 3/4 in (19 mm) E

E 32-3/4 in (832 mm) 25°

F 45-1/2 in (1156 mm)

564 lb (256 kg) Engine End 800 426

3-3. Generator Power Curve

3-4. Fuel Consumption

TM-404 Page 4 Bobcat 225D Plus

3-6. Volt-Ampere Curves

B. For CC/DC Mode C. For CV/DC Mode

166 024-A / 166 025-A / 166 026-A

Bobcat 225D Plus TM-404 Page 5

Y Do not use flexible mounts. 1

Electrically bond generator frame to

TM-404 Page 6 Bobcat 225D Plus

Store battery in warm area off

Use fuel formulated for cold

Use correct grade oil for cold

Ref. 151 983 / Ref. 801 331-G

Bobcat 225D Plus TM-404 Page 7

. When electrolyte is low, add

drybatt1 2/96 − S-0886

TM-404 Page 8 Bobcat 225D Plus

Y Connect negative (−)

4-5. Connecting To Weld Output Terminals

801 458-A / Ref. 192 785

Bobcat 225D Plus TM-404 Page 9

2 ea. 2/0 2 ea. 2/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

TM-404 Page 10 Bobcat 225D Plus

Glow Plug Time

Ref. 192 785 / Ref. 801 434

Bobcat 225D Plus TM-404 Page 11

. Generator power decreases

6 Set Fine Adjust control R1 at 10

120V 240V Y Power is still present at the

Ref. 192 785

TM-404 Page 12 Bobcat 225D Plus

Weld Current Total Power 120V 240V

See Owner’s Manual for additional information.

Bobcat 225D Plus TM-404 Page 13