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OM-404 Page 44

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 11-1. Main Assembly (Continued)

Quantity

48

172 714

BRACKET, engine mounting

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

49

172 719

BRACKET, mtg engine lower

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

50

127 854

CLAMP, stl cush 1.312dia x .343mtg hole

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

51

172 720

BRACKET, mtg engine upper

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

52

172 625

BRACKET, mtg rectifier/components

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

53

1T

172 661

BLOCK, stud connection 6 position

1

. . . 

. . . . . . . 

. . . . . . . 

. . . 

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

54

173 734

LINK, jumper

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

55

SR1

192 682

RECTIFIER, si 1 ph 240A 400PIV

1

. . . 

. . . . . . . 

. . . . . . 

. . . 

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

56

180 628

PANEL, front lower

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

57

Fig 11-2

PANEL, front w/components

1

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. . . 

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

58

CT1

179 494

TRANSFORMER, current sensing

1

. . . 

. . . . . . . 

. . . . . . 

. . . 

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

59

177 136

CLAMP, capacitor 2.500dia clip

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

60

C1

176 719

CAPACITOR, elctlt 1000uf 75VDC

1

. . . 

. . . . . . . 

. . . . . . . 

. . . 

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

61

172 731

HOLDER, fuse mintr

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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

62

F1

*169 296

FUSE, mintr gl 25A 125V

1

. . . 

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. . . . . . 

. . . 

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

63

SR2,3

200 759

RECTIFIER, integ 35A 600V

2

. . . 

. . . . . . 

. . . . . 

. . . 

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

64

R2

184 278

RESISTOR, WW adj 225W 5 ohm

1

. . . 

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. . . . . . . 

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

RC4

116 045

CONNECTOR & PINS

1

. . . . . . . . . . . . 

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. . . 

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PLG6

136 810

CONNECTOR & PINS

1

. . . . . . . . . . . . 

. . . . . 

. . . 

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

PLG4

135 556

CONNECTOR & SOCKETS

1

. . . . . . . . . . . . 

. . . . . 

. . . 

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

RC6

168 844

CONNECTOR, rect 4 pin/skt rcpt

1

. . . . . . . . . . . . 

. . . . . . 

. . . 

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

207 503

KIT, label

1

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

. . . 

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

65

197 930

LABEL, warning do not weld on base

2

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

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OPTIONAL

+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.

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 57)

Quantity

1

S1

184 754

SWITCH, polarity 5 position (Weld Process)

1

. . . 

. . . . . . . 

. . . . . . . 

. . . 

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

2

NAMEPLATE, (order by model and serial number)

1

. . . 

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

. . . . . . . . . . . . . . . 

3

207 845

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

. . . 

. . . . . . . . . . . . . . . . 

. . . 

. . . . 

3

203 681

PANEL, front (w/CSA receptacle option)

1

. . . 

. . . . . . . . . . . . . . . . 

. . . 

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

4

186 058

COVER, dust

2

. . . 

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. . . 

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

5

S3

183 148

SWITCH, selector 4 position (Coarse Adjustment)

1

. . . 

. . . . . . . 

. . . . . . . 

. . . 

. . . . . . . . . . . . . . . 

6

R1

117 243

RHEOSTAT, WW 100W 10 ohm (Fine Adjustment)

1

. . . 

. . . . . . . 

. . . . . . . 

. . . 

. . . . . . . . . . . . . . 

7

PC1

186 224

MODULE, weld/power 7 pin

1

. . . 

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. . . . . . 

. . . 

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8

CR1

173 069

RELAY, encl 12VDC SPDT 15A 125VDC

1

. . . 

. . . . . . 

. . . . . . 

. . . 

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

9

S2

176 606

SWITCH, ignition 4 position w/out handle (Engine)

1

. . . 

. . . . . . . 

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. . . 

. . . . . . . . . . . . . . . 

10

RC2,3

141 432

RECEPTACLE, str dx grd 2P3W 20A 125V

2

. . . 

. . . . . . 

. . . . . 

. . . 

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

10

GFCI2,3

151 981

RECEPTACLE, str dx grd 2P3W 15/20A 125VAC GFI

2

. . . 

. . . . . 

. . 

. . . 

. . . . . . . . . . . 

11

CB1,2

195 955

CIRCUIT BREAKER, man reset 1P 50A 125VAC

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

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

. . . 

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

12

CB3,4

093 996

CIRCUIT BREAKER, man reset 1P 20A 250VAC

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

. . . 

. . . . . . . 

. . . . . . . 

. . . 

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

021 385

BOOT, tgl switch lever

1

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

. . . 

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

14

CB8

083 432

CIRCUIT BREAKER, man reset 1P 10A 250VDC

1

. . . 

. . . . . . . 

. . . . . . 

. . . 

. . . . . . . . . . . . . . . 

15

HM

145 247

METER, hour 12-24VDC

1

. . . 

. . . . . . . 

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. . . 

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

Summary of Contents for Bobcat 225D PLUS

Page 1: ...Processes Description Non Critical TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 404 175 611T April 2002 Visit our website at www Mill...

Page 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself again...

Page 3: ...Activating The Dry Charge Battery If Applicable 14 4 4 Connecting The Battery 15 4 5 Connecting To Weld Output Terminals 15 4 6 Selecting Weld Cable Sizes 16 SECTION 5 OPERATING WELDING GENERATOR 17...

Page 4: ......

Page 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Page 6: ...uch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FI...

Page 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...quer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du co...

Page 10: ...pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut...

Page 11: ...nir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniqueme...

Page 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 13: ...AC Output Time h Hours s Seconds Protective Earth Ground Do not switch while welding Welding Arc Electrode Work Connection SECTION 3 SPECIFICATIONS 3 1 Weld Power and Engine Specifications Welding Mod...

Page 14: ...perate unit where it could tip B 16 1 2 in 419 mm 4 Holes tip C 3 4 in 19 mm E D 3 1 8 in 79 mm F E 32 3 4 in 832 mm 25 F 45 1 2 in 1156 mm 25 G 13 32 in 10 mm Dia 25 25 25 Weight 564 lb 256 kg 800 42...

Page 15: ...damage unit and void warranty 100 Duty Cycle at 225 Amperes CC AC 210 Amperes CC DC 200 Amperes CV DC 3 6 Volt Ampere Curves 166 024 A 166 025 A 166 026 A The volt ampere curve shows the minimum and m...

Page 16: ...ator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insul...

Page 17: ...l 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 allo...

Page 18: ...ery 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 Read and follow all instruc tions supplied with ba...

Page 19: ...1 458 A Ref 192 785 1 Work Weld Output Terminal 2 Electrode Weld Output Terminal Connect work cable to Work terminal Connect electrode holder cable or electrode weld cable to Electrode terminal for St...

Page 20: ...0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2...

Page 21: ...ne starts If the engine does not start let engine come to a complete stop before attempt ing restart Move idle lock switch to Run Idle after engine warms To stop move engine control switch to Off 4 We...

Page 22: ...rom 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 RC1 and one of the 120 volt receptacles d...

Page 23: ...en contact Factory Authorized Service Agent 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects RC2 and CB3 pro tects RC3 from overload If a circuit breaker opens the receptacle does not work Pre...

Page 24: ...pens to disconnect the faulty equipment Check for damaged tools cords plugs etc connected to the receptacle Press button to reset receptacle and resume operation At least once a month run engine at we...

Page 25: ...tacle shares a load with one half of 240 V receptacle 2 Plug Wired For 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Terminal 7 Amperes Ava...

Page 26: ...ere conditions To be done by Factory Authorized Service Agent 8 h Wipe Up Spills Check Fluid Levels See Section 4 2 Service Air Filter 50 h Clean And Tighten Weld Terminals Service Air Filter Element...

Page 27: ...4 Page 23 500 h Repair Or Replace Cracked Cables And Cords Clean Set Injectors Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions 1000 h Blow Out Or Vacuum Inside...

Page 28: ...tructions on filter Engine RPM No Load Weld Power 3750 Idle 2000 Air Filter Service 50 hours or less see Owner s Manual Injectors MILLER 066 852 Deutz 77 644 56 Have only trained technician maintain i...

Page 29: ...ol 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...

Page 30: ...at either oil fill 6 Fuel Line 7 Primary Fuel Filter Replace line if cracked or worn Install new filter Wipe up any spilled fuel 8 Secondary Fuel Filter Remove filter and install new filter element a...

Page 31: ...Weld Power Speed Jam Nut Loosen jam nut Turn screw clock wise to decrease speed and coun terclockwise to increase speed Tighten jam nut Stop engine 2000 rpm 3750 rpm 1 4 in 8mm 3 4 2 1 Right Side Tool...

Page 32: ...it usually indicates a more seri ous problem exists Contact a Factory Authorized Service Agent 801 458 A Ref 192 785 1 C Fuse F1 Ref 801 477 C Stop engine and disconnect battery negative cable Remove...

Page 33: ...to electrode and workpiece Use dry properly stored electrodes for SMAW and GTAW Remove excessive coils from weld cables Tighten and clean connections both inside and outside welding generator Check a...

Page 34: ...s between uses Clean battery terminals and posts with baking soda solution rinse with clear water Periodically recharge battery approximately every three months Have Factory Authorized Service Agent c...

Page 35: ...OM 404 Page 31 SECTION 8 ELECTRICAL DIAGRAM SC 182 630 B Figure 8 1 Circuit Diagram For Welding Generator...

Page 36: ...e Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 9 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Te...

Page 37: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 9 8 3 Rating Data Rating shows volts...

Page 38: ...me Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mil...

Page 39: ...6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 H...

Page 40: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 41: ...9 11 6 Generator Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator...

Page 42: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 43: ...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 generatoris...

Page 44: ...on 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 Set load b...

Page 45: ...r 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 Start engine and run for severa...

Page 46: ...OM 404 Page 42 SECTION 11 PARTS LIST ST 801 516 K 65 Figure 11 1 Main Assembly...

Page 47: ...elec start 1 19 142 322 BRACKET mtg fuel filter 1 20 BASE fuel filter see engine parts list 1 21 066 893 ELEMENT fuel filter 1 22 165 271 VALVE oil drain 3 8 18NPTF 1 23 172 634 FITTING adapter oil d...

Page 48: ...Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Description Part No Dia Mkgs Item No Figure 11 2 Panel Front w Components Fig 11 1 Item 57...

Page 49: ...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 27 200 532 LABEL warning CSA circuit breaker 1 ST 801 5...

Page 50: ...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...

Page 51: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact...

Page 52: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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