Miller BOBCAT 225G PLUS W/KOHLER ENGINE Owner's Manual

Miller
OM-175104A
Form:
June1996
Effective With Serial No. KG1 60360
OWNERS
MANUAL
Bobcat1M
225GP~
(Kohier-Powered)
CCICV ACIDC
Welding
Mode
Welding
Weld
Rated
Output
Range
Welding
Output
Generator For
SMAW, FCAW, GMAW, GTAW Welding
Maximum
OpenCircuit
Auxiliary Power
Rating
Fuel
Capacity
Engine
Voltage
225A,25V,
CC/AC
50225
A
Duty
Cycle
100%
80
~
210
CC/DC
50
210 A
A, 25 V,
Duty
Cycle
100%
Single-Phase,
kVNkW, 70/35 A,
120/240 V AC, 60Hz
72
8
8.5
gal (32 L)
Tank
KohlerCHl8
Air-Cooled, Two-Cylinder,
Four-Cycle, 18 HP
Gasoline Engine
200A,20V,
CV/DC
cover_om 4/95
17-28V
Ref. ST-801 188
100%Duty
Cycle
33
'
1996 MILLER Electric
Mfg.
co.
PRINTED IN USA
s-f
TRUE BLUEfi LIMITED WARRANTY
MILLERS
(Equipment
supersedes
This limited warranty
with
Effective February 7, 1996
serial number preface of lCD
all previous MILLER warranties end is exclusive with
Subject to theterms and conditions below, MILLER Electric
to its original retail purchaser that new
date ot this limited warranty is free of de
fecta in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
no
newer)
or
e
other gusrsntees
LIMITED WARRANTY
5.
6 Months
Mfg. Co., Appleton, Wisconsin, warrants
MILLER equipment sold after the effective
6.
90
warranties
or
expressed
or
implied.
Batteries
Parts end Labor
Days
MIG GunalflG Torches
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
IMPUED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
Remote Controla
Accessory Kits
Replacement Parta
Within the warranty periods listed below, MILLER will repair or replace any war
ranted parts orcomponents thatfail due to such defects in material orworltnisnship.
MtLLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
MILLERS
MILLER shall honor warranty claims
event of such a failure within the
start on the date that the
on
True Bluefi umited
Warranty
shall not
apply
to:
by MILLER, but manufactured by others, such as engines or
trade accessories. These items are covered by the manufacturers warranty, if
Itema fumiahed
1.
followed.
any.
warranted equipment listed below in the
warranty time periods. All warranty time periods
equipment
was
delivered to the
original
retail purchaser,
year after the equipment is sent to a North Amencan distributor
months after the equipment is sent to an Intemahonal distributor.
one
or
2.
or
Consumable components; such
and
eighteen
relays
or
ax
contact
parts that fail due to normal
tips, cutting nozzles,
contactors
wear.
by any party other than MtLLER, or equipimproperiy installed, improperiy operated or misused
based upon industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
3.
Equipment that
has been modified
meet that has been
1.
main power rectifiers
Original
Inverters
2.
Years Labor
5 Years Parts 3
3 Years
*
and output rectifiers
(input
only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIALI1NDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
Parts and Labor
Transformer/Rectifier Power Sources
Plasma Arc
Cutting
THE USE AND MAINTENANCE OF WELDING EQUtPMENT.
Power Sources
3.
sirall be, at MILLERS
writing by MILLER in
Supplies
Inverter Power
appropriate cases, (3) the reasonable coat of repair or replace
station; or (4) payment of orcredit forthe pur
price (less reasonable depreciation based upon actual use) upon retum of the
goods at customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for transportation costa of any kind will be allowed.
Infellitig
ment at an authonzed MILLER service
Robots
chase
2 Years
(1
labor)
year
Parts and Labor
Engine Driven Welding Generators
(NOTE: Enginea are warranted aeparstely by the engine manufacturer.)
Air
4.
warranty claim covered by this warranty, the exclusive remedies
option: (1) repair; or (2) replacement; or; where authorized in
In the event of a
Semi-Automatic and Automatic Wire Feeders
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE TI-fE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT INDIRECT, SPECIAL, INCIDENTALOR CONSEDUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACt TORT OR ANY OTHER LEGAL THEORY.
Compressors
1 YearPartaand
Labor
Motor Driven Guns
Process Controllers
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
IHPS Power Sources
Water Coolant
-
Systems
REMEDY FOR BREACH OF CONTRACT TORT DR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHTARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
HF Units
Grids
Spot
Welders
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EGUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Load Banks
SDX Trsnafonners
Miller
Cyclomatic Equipment
Plasma
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, ao
Gear/Trailers
Running
Cutting
Torches
cific
Engines
Deutz Engines (outside
North
Amenca)
In
legal rights,
waived,
as
provinces provides for certain additional warranties
they may not be
apply. This Limited
ataled herein, and to the extent that
the limitations and exclusions aet out above may not
Warranty provides specific legal rights,
vary from province to province.
greater.)
whichever is
rights
in some
remedies other than
or
(NOTE: Field optiona are covered under True Bluefi for the remaining
warranty period of the product they are installed in, or for a minimum of
year
and other
Canada, legislation
Field Optiona
one
apply to you. This warranty provides ape
may be available, but may vary from state to state.
the above limrtahon or exclusion may not
(except AFT, ZIPCUT & PLAZCUT Modela)
Tecumaeh
and other
rights may
be available, but may
r...
1il
L
WHO DO I CONTACT?
For
To file
help,
a
claim for loss
contact the
For
additional information, such
Technical ManUa)S
Engine
(Service
And
damage during
,
as
Parts)
delivering
For assistance in
filing
or
manUfactUrers
Wiring Diagrams
Miller Electric
~j~~j9)
carner
Mfg.
Co.
CALL:
4147354505
settling claims,
contact your distributor and/or
Manuals
Circuit And
or
shipment,
contact your diStribUtor
equipment
Transportation
Department
jZT1
FAX:
800-637-2348
414-735-4136
(in USA), or
(outside USA)
Process Handbooks
Users
Guides
o~
Distributor Directories
WRITE:
Miller Electnc
Mfg.
Co.
P.O. Box 1079
contact your distributor
Appleton,
Always provide
Model Name and Serial
or
Style
WI 54912 USA
Number
miller_wan
3/96
TABLE OF CONTENTS
SECTION 1
1-1.
-
SAFETY PRECAUTIONS FOR ARC WELDING
1-3.
Symbol Usage
Welding Hazards
Engine Hazards
1-4.
Additional Installation,
1-2.
1
Arc
1
2
Operation,
And Maintenance Hazards
Standards
1-5.
Pnncipal Safety
1-6.
EMF Information
Symbol
3
4
Definitions
4
SECTION 3-INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3
3
SECTION 2- DEFINITIONS
2-1.
1
5
Generator
Installing Welding
Dimensions, Weights, And Operating Angles
Fuel Consumption
Engine Prestart Checks
Connecting The Battery
Weld Output Terminals And Selecting Cable Sizes
SECTION 4-OPERATING WELDING GENERATOR
5
5
6
6
7
7
8
4-1.
Front Panel Controls
8
4-2.
Duty Cycle
9
SECTION 5-OPERATING AUXILIARY EQUIPMENT
Standard
10
Receptacles
Optional Auxiliary Power Receptacles
Wiring Optional 240 Volt Plug
10
SECTION 6- MAINTENANCE AND TROUBLESHOOTING
13
5-1.
5-2.
5-3.
11
12
6-1.
Routine Maintenance
13
6-2.
Maintenance Label
14
6-3.
6-5.
Servicing Air Cleaner
Changing Engine Oil, Oil Filter,
Adjusting Engine Speed
6-6.
Overload Protection
6-7.
Inspecting And Cleaning Optional Spark
Troubleshooting
6-4.
6-8.
14
And Fuel Filter
15
16
17
Arrestor
17
18
SECTION 7- ELECTRICAL DIAGRAM
20
SECTION 8- PARTS LIST
21
OM-175 104A-6/96
SECTION 1
SAFETY PRECAUTIONS FOR ARC WELDING
-
safety_romi
1-1.
Symbol Usage
4A
~~
1-2.
4/95
Means Warning! Watch Out! There
procedure! The possible hazards are
Arc
possible
hazards with this
shown in the
adjoining symbols.
are
Marks
A
a
special safety
~ Means NOTE; not
message.
I
safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
I
actions to avoid the hazards.
Hazards
Welding
WARNING
£~
The symbols shown below are used throughout this manual to call attention to and identify possible hazards.
When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety
information given below is only a summary of the more complete safety information found in the Safety
Standards listed in Section 1-5. Read and follow all Safety Standards.
Only qualified
persons should
install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children
ELECTRIC SHOCK
can
kill.
terminal in disconnect box
fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
Touching
electrical
live
away.
parts
can
7.
equipment
use
worn,
grounding
15. Wear
a
Owners
16.
Keep
all
17.
Clamp
oower
cord around wire is
~
check and be
sure
that
orooerlv connected to
input
use.
or
poorly spliced
with
separate cable
a
your body.
workpiece is required, ground it directly
do not use work clamp or work cable.
over
of the
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
only well-maintained equipment. Repair
damaged parts at once. Maintain unit according to
14. Use
around
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
grounding
cables.
drape cables
supply ground
when not in
damaged, undersized,
12. If earth
the
proper
Turn off all
10. Do not
11. Do not
Manual and national, state, and local codes.
attach
9.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
Always verify
a
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Do not touch live electrical parts.
6.
is connected to
8.
Wear
5.
plug
double-check connections.
conductor first
1.
4.
that cord
making input connections,
When
2.
3.
or
properly grounded receptacle outlet.
cause
safety
harness if
covers
cable
with
panels
work
workoiece
or
working
and
worktable
replace
above floor level.
securely
in
place.
metal-to-metal
good
as near
or
manual.
the weld
contact
to
oractical.
as
ARC RAYS
2.
Wear
a
welding
helmet fitted with
a
proper shade of filter to
protect your face and eyes when welding orwatching (see ANSI
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin. Noise from some
3.
Wear
damage heanng. Chipping,
welds cooling throw oft pieces of
4.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5.
Wear
processes
grinding,
metal
or
Z49.1 and Z87.1 listed in
Safety Standards).
approved safety glasses
with side shields.
can
and
slag.
NOISE
1.
Use
approved
r
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
can
high.
be hazardous
5.
to your health.
6.
2.
If inside, ventilate the area and/or
remove welding fumes and gases.
3.
If ventilation is poor,
use an
Read
Safety
4.
the
Material
manufacturers
exhaust at the
arc
to
7.
approved air-supplied respirator.
Data Sheets
(MSDS5)
and
confined space only if it is well ventilated,
the
coatings,
or
while
an
Do not weld in locations
operations.
form
use
instruction for metals, consumables,
cleaners, and degreasers.
a
air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
your head out of the fumes. Do not breathe the fumes.
Keep
Work in
wearing
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1.
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
material
highly
Do not weld
cadmium
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
on
or
spraying
react with vapors to
coated metals, such
plated steel, unless
weld area, the
can
area
the
as galvanized, lead, or
coating is removed from the
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-175 104
Page
1
CYLINDERS
1.
2.
3.
Protect
explode if damaged.
Never
5.
Never allow
6.
Never weld
7.
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
8.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
can
a
a
9.
cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
10. Read and follow instructions
Install
in
can cause
fire
explosion.
or
closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly oft from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and bums. Accidental contact of electrode to metal
Welding
objects
or
connected for
associated
can cause
sparks, explosion, overheating,
any
equipment,
sure
the
use.
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
1.
Protect
Do not weld where
and others from
3.
Remove all flammables within 35 ft
flying sparks
flying sparks
can
and hot metal.
strike flammable material.
(10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Engine
welding
fire
on
on a
ceiling, floor, bulkhead,
or
partition
the hidden side.
on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS F4.1
(see Safety Standards).
7.
Do not weld
8.
Connect work cable to the work
9.
Do not
as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
is safe before
area
that
aware
can cause
welding.
2.
yourself
Be
6.
on
fire. Check and be
doing
1 -3.
use or
Standards.
WELDING
5.
drape
mechanical shocks,
circuits.
4.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
on a pressurized cylinder
explosion will result.
4.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
welder to thaw frozen
use
pipes.
10. Remove stick electrode from holder
contact
tip
or
cut off
welding
wire at
when not in use.
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
11. Wear oil-free
12. Remove any
combustibles, such
from your person before
as a
lighter or matches,
butane
doing any welding.
Hazards
WARNING
a
____
ENGINE EXHAUST GASES
Engines
can
kill.
pr oduce harmful exhaust gases.
ENGINE
FUEL
can
cause
fire
or
fuel is
closed area, vent engine exhaust outside and
away from any building air intakes.
2.
highly flammable.
Sto p eng me and let it cool off before
MOVING PARTS
3.
checking
or a
can cause
dding
fuel.
injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
2.
Keep all doors, panels,
securely in place.
covers,
Stop engine before installing
or
and
guards
3.
connecting
~ ~/,.
4.
OM-175 104
Page
Do not
spill
fuel. If fuel is
if unit is
near
any sparks
or
clean up before
starting
only qualified people remove guards or covers for
troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative () battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when
finished and before starting engine.
1.
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
2.
servicing
is
cables.
sparks when working on a battery.
charge batteries or jump start vehicles.
polarity (+ and ) on batteries.
Do not allow tools to
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
generate explosive
spilled,
expand.
Have
4.
2
or
6.
unit,
It is best to check coolant level when eng me is
cold to avoid scalding.
~
smoking
allow room for fuel to
Do not overfill tank
3.
Batteries contain acid and
,
Do not add fuel while
maintenance and
closed and
SPARKS can cause BATTERY GASES
TO EXPLODE; BATrERY
ACID can
burn eyes and skin,
~
areas.
a
engine.
5.
1.
If used in
open flames.
4.
1.
in open, well-ventilated
Use
explosion,
Engine
equipment outside
1.
2.
If the
use
cause
welder to
engine
is
warm
and
checking
and
gloves
is needed, follow steps 2
and 3.
2.
Wear
3.
Turn cap
safety glasses
slightly and let
completely removing cap.
and
put
a
rag
pressure escape
over
cap.
slowly
before
1-4.
Additional Installation,
WARNING
a
MOVING PARTS
1.
Operation, And Maintenance Hazards
can cause
READ INSTRUCTIONS.
injury.
Before
working of generator, remove spark plugs
or injectors to keep engine from kicking back or
starting.
Block flywheel so that it will not turn while working
on
1.
Use
2.
Reinstall
DIRT
or
Wear
1.
safety glasses
with side shields
or
air from fuel
system
DO NOT LET ENGINE EXHAUST SPARKS
CAUSE FIRE.
can
injure eyes.
1.
injectors and bleed
to engine manual.
according
generator components.
FLYING PIECES OF METAL
only genuine MILLER replacement parts.
face
Use approved engine exhaust spark arrestor
required areas see applicable codes.
in
shield.
STATIC ELECTRICITY
on circuit boards.
1.
Put
can
grounded wrist strap BEFORE handling
parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
on
boards
or
MAGNETIC
CURRENTS
LOW VOLTAGE AND FREQUENCY CAN
DAMAGE electrical equipment such as
J~
damage parts
MOTORS.
~{J~ ~IJ
1.
-~--
2.
Wearers should consult their doctor before
near
arc
wearers
keep away.
welding, gouging,
or
going
spot welding
can
or
OVERHEATED
cause
EQUIPMENT.
1.
Allow
2.
Reduce current
operation.
Pacemaker
or unplug equipment before starting
stopping engine.
OVERUSE
HIGH
FIELDS
FROM
affect
can
pacemaker
1.
Turn off
I
I
cooling period.
starting
3.
to weld
Follow rated
or
reduce
duty cycle before
again.
duty cycle.
operations.
HOT PARTS
1.
2.
can cause severe
Allow
TILTING OF TRAILER
burns.
cooling period
maintaining.
gloves and clothing when working
hot engine.
Wear protective
on a
Use
2.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
1-5.
or
blocks to support
BURN
can
weight.
SKIN
AND
Donottip.
2.
Replace damaged battery.
3.
Flush eyes and skin
immediately
with water.
Standards
Safetyin Welding and Cutting, ANSI Standard Z49.i,from
Welding Society, 550 N.W. LeJeune Ad, Miami FL 33126
American
Safety and Health Standards, OSHA 29 CFR 1910, from
Supenntendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6.
1.
Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift unit.
Principal Safety
tongue jack
BATTERY ACID
EYES.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
1.
injury.
can cause
1.
before
Safe
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code forSafetyin Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontano, Canada M9W 1 R3.
Safe Practices For
Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1 from American National Standards
Institute, 1430 Broadway, New York, NY i0018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
EMF Information
Considerations About
Welding
Electric And
Fields
The
Magnetic
And The Effects Of Low
Frequency
To reduce
magnetic fields
in the
workplace,
use
the
following
procedures:
1.
Keep
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
.
following is a quotation from the General Conclusions Section of
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Elect tic & Magnetic Fields Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
Office, May 1989):... there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
the U.S.
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.
cables close
cables to
or
together by twisting
or
taping
them.
side and away from the operator.
one
drape cables around the body.
clamp
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers.
The
above
wearers.
procedures
are
also
recommended
for
pacemaker
Consult your doctor for complete information.
OM-175 104
Page
3
SECTION 2- DEFINITIONS
2-1.
Symbol
OM-175 104
Page
4
Definitions
SECTION 3-INSTALLATION
3-1.
3-2.
Installing Welding Generator
Dimensions, Weights, And Operating Angles
Dimensions
Height
31 in
(787 mm)
A
Do
not
running
Width
6-3/4 in
(476 mm)
A
Do not
operating angles while
engine damage will occur.
exceed
or
move or
operate unit where it could
tip.
Depth
A
Engine
46 in
18 in
(1164 mm)
(457 mm)
B
6-1/2 in
C
3/4 in
D
3-1/8 in
E
32-3/4 in
(419 mm)
(19 mm)
(79 mm)
Weight
(832 mm)
End
F
ST-800 426
a
45-1/2 in
13/32 in
(1156 mm)
(10mm)
Dia.
Net: 567 lb
Ship:
608 lb
(258 kg)
(276 kg)
OM-175 104
Page
5
3-3.
Fuel
Consumption
7.57
1.67
2.00
6.62
1.46
1.75
5.67
1.25
1.50
4.73
1.04
1.25
3.78
0.84
1.00
.AUX POWER
3750 RPM
~CW~LD
~
;;~
.
0.75
1.89
0.42
0.50
0.95
0.21
0.25
I
I
~
~
~
~
______
0.63
3750RPM
~
¶
~
_______
2.84
DC WELD
3750 RPM
-
CV WELD
3750RPM
-
IDLE
2200 RPM
10
0
25
50
75
100
125
150
175
200
225
250
275
10.0
11.0
WELD AMPERES AT 100% DUTY CYCLE
Q-
Cl)
I
I
I
I
I
0
1.0
2.0
3.0
4.0
5.0
I
I
6.0
7.0
8.0
POWER KVA AT 100% DUTY CYCLE
3-4.
Engine
OM-175 104
Page
6
Prestart Checks
9.0
Ref. SB.179 939
3-5.
3-6.
The
Connecting
Weld
.d.~,,
~
Output
A
~
~I
Battery
Terminals And
ARC WELDING
Selecting Cable Sizes
can cause
Electromagnetic Interference.
To reduce
possible interference, keep weld cables as short as possible, close together, and down low, such as on the
floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is
installed and grounded according to this manual, If interference still occurs, the user must take extra measures such
as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
~
Total Cable
!
Weld
~
Output
lOOft30
Terminals
1060%
w elding
Less
In Weld Circuit Not
Exceeding
150ft
200ft
250 ft
300ft
350ft
400ft
(45 m)
(60 m)
(70 m)
(90 m)
(105 m)
(120 m)
60100%
Duty
Cycle
Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
peres
WORK
m,Or
(Copper) Length
10
100%
Duty Cycle
ELECTRODE
ST-800 396-A
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.
5-0007-0
OM-175 104
Page
7
SECTION 4- OPERATING WELDING GENERATOR
4-1.
Front Panel Controls
I
00 NOT SWITCH
UNDER LOAD
COARS
-~DJUST
ENGINE
FINE ADJUST
TotaiAllLoads8O
A
+
STiCK/Tb
240V\.,
Watts
120V\.,
120V\,
WIRE
a
D:1HI~l
i
IIIHEII
~
.In*canwT.yps~ThE
AC POWER
CESS
3
Ref. ST-i 78 079-A
1
Engine Control
Switch
Use switch to start engine, select speed,
and stop engine. In Run/Idle position,
engine runs at idle speed at no load, and
weld/power speed under load. In Run
position, engine runs at weld/power speed.
Place switch in Run
most GMAW
position
equipment.
to
operate
engine starts. Do not crank engine if engine
is still turning. Set anti-icing control (see
Section 3-4).
To
Stop:
Engine
Choke Control
Use control to
3
change engine air-fuel
mix.
OM-175 104
slowly push
Page
8
choke in
when
~ For
Use switch to select type of weld output.
positive (+) position for Direct Current
(DCEP) and a negative
() position for Direct Current Electrode
Negative (DCEN). Use AC position for
alternating current.
4
Sticking position, or voltage range
switch is in Wire position.
a
Coarse
Adjust
Switch
best
arc
amperage range
Weld Process Selector Switch
Electrode Positive
To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and
Engine
Control switch to Off
position.
Use
2
turn
Use switch to select weld amperage range
when Weld Process Selector switch is in
5
Fine
Adjust
starts,
use
when
lowest
possible.
Control
Use control to select weld amperage (Stick/
flg) or voltage (Wire) within the range se
lected by the Coarse Adjust switch. Control
may be adjusted while welding. Weld output
would be 110 A DC based on control set
tings shown (50% of 70 to 150 A).
6
Engine
Hour Meter
4-2.
Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
250
225
0
Ui
A Exceeding duty cycle
damage
Ac/cc
_______
210
ocicc
~200
DC/CV
~
unit
and
can
void
warranty.
Ui
150
10
15
20
25
30
40
50
60
70 60 SO 100
X DUTY CVCLE
100%
Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CVIDC
0
Continuous
Welding
SB-119 454-A
OM-175 104
Page
9
SECTION 5- OPERATING AUXILIARY EQUIPMENT
5-1.
Standard
Receptacles
_______________
~
Auxiliary power
decreases
as
weld current increases.
Set Fine Adjust control Ri at
10 for full auxiliary power.
12OV15AAC Receptacles
GFCI-2 And GFCI-3
1
GFCI-2 and GFCI-3
IOTAL
00
240V~
supply 60 Hz
single-phase power at weld/power
speed. Maximum output from each
receptacle is 2.4 kVAJkW (CSA:
1.8 kVA/kW).
4
A
ALL
LOADS 8000 !M~T~S
o
120V~
o
120V%,
If a ground fault is detected, Reset
button pops out and the circuit
opens to disconnect the faulty
equipment. Check for faulty tools,
cords, etc. connected to the
receptacle. Press reset button to
resume
operation.
~ At least
engine
once
month,
a
run
weld/power speed
and press Test button to verify
GFCI is working properly.
____________
_____________
2
at
240 V 50 A AC
Receptacle
RC1
RC1
supplies
60 Hz
single-phase
at
weld/power speed.
power
Maximum output is 8 kVA/kW.
3
~tC POWER
______________________________________________________________________________
Circuit Breakers CB1 And
CB2
CB1 and CB2 protect RC1 from
overload. If CB1 or CB2 opens,
RC1 and one of the 120 volt recep
tacles does not work.
120 volts
may still be present at RC1.
4
Circuit Breakers CB3 And
CB4
CB3 and CB4 protect GFCI-2 and
GFCI-3 from overload. If CB3 or
CB4 opens, the receptacle does
not work.
fl~ If a circuit breaker continues to
open, contact a
Authorized Service
Factory
Agent.
Total output of receptacles limited
to 8 kVNkW. Example: If 20 A is
drawn from GFCI-2 and GFCI-3,
only 13 A is available at RC1:
2x(12OVx2OA)+(240Vx 13A)
=
7.9 kVA/kW
Ret. ST-178 079-A
OM-175 104
Page
10
5-2.
Optional Auxiliary
Power
Receptacles
A
If unit does not have GFCI
GFC1use
receptacles,
protected extension cord.
~
Auxiliaiy power
decreases
as
weld current increases.
Set Fine Adjust control Ri at
10 forM! auxiliasy power.
Totai Au Loads 8000 Watts
240V\.,
120V\.,
120V\.
Combined output of all receptacles
limited to 8 kVA/kW rating of the
generator.
120 Volt
Receptacle Option
120 V 15 A AC
1
Receptacles
RC2 And RC3
__Ho
RC2 and RC3 supply 60Hz singlephase power at weld/power speed.
Maximum output from RC2 or RC3
is 2.4 kVA/kW (CSA: 1.8 kVAIkW).
Circuit breaker protection is the
same as standard receptacles.
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
Receptacles
atov~
RC1
RC2, And
RC3
\
~
Receptacles supply 60 Hz singlephase power at weld/power speed.
Maximum output from each recep
5
tacle is 3.6 kVNkW.
4
Circuit Breakers CB1, CB2,
CB3
CB1, CB2, and CB3 protect Rd.
RC2, and RC3 from overload. If a
circuit breaker opens, the recep
tacle does not work. Press button
to reset breaker.
AC
POWER
5
Circuit Breaker CB4
CB4
protects
all the
receptacles
from overload. If CB4 opens,
of the receptacles work.
none
~ If a circuit breaker continues to
open, contact a
Authorized Service
Factory
Agent.
3
AC
POWER
Ref. ST-172 786-B I Ref. ST-i 81 714
OM-175 104
Page
11
5-3.
Wiring Optional
240 Volt
Plug
The
plug
can
2-wire load
7
load. See circuit
1
Current Available In
240 V
Amperes
Duplex
Receptacle
with
35
0
30
5
25
10
20
15
15
20
V
x
One 240 V load
A
=
or
diagram.
Wired For 120/240 V,
3-Wire Load
Plug
When wired for 120 V loads, each
duplex receptacle shares a load
Each 120 V
Receptacle*
a 240 V,
120/240V, 3-wire
be wired for
or a
2
one
Plug
half of 240 V
receptacle.
Wired For 240 V, 2-Wire
Load
5
Terminal
3
Neutral
(Silver)
4
Load 1
(Brass)Terminal
5
Load 2
(Brass) Terminal
6
Ground
7
Amperes Available Using
120/240 V Plug
I-
Watts
two 120 V loads.
6
(Green) Terminal
5
Tools Needed:
===~_
ST-120 813-0
OM-175 104
Page
12
SECTION 6- MAINTENANCE AND TROUBLESHOOTING
6-1.
Routine Maintenance
A Stop engine before maintaining.
Recycle engine
fluids.
See also
nance
during
fi
Engine
Manual and mainte
label. Se,vice engine more often
severe
conditions.
20h
50h
lOOh
fi
200h
500h
4
Repair Or Replace
Cracked Cables.
l000h
OM-175 104
Page
13
6-2.
Maintenance Label
KOHLER CH18 GAS ENGINE
+
BClGroup58
l2VoltBattery
r-i
J
Cranking
Performance at 0F
(-18C)
...
.
430
Amps
mm.
6-3.
Servicing
Air Cleaner
A Stop engine.
A
Do not run
air cleaner
element.
1
Precleaner
engine without
with dirty
or
2
Wash
with soap and
precleaner
water solution. Allow
air
L__~
precleaner to
dry completely.
Spread
evenly
1
tablespoon SAE 30 oil
precleaner. Squeeze
into
out excess oil.
2
Element
Replace element
-,
-4
Page
14
dirty
or
oily.
-4
aircleaner3 4/96
OM-175 104
if
ST-i 56 852/ S-0759
6-4.
Changing Engine Oil,
Oil Filter, And Fuel Filter
A Stop engine
1
and let cool.
Oil Drain Valve
2
1/2lDxl2inHose
3
Oil Filter
4
Oil Fill
5
Oil
Cap
Dipstick
Change engine
cording
to
engine
oil and filter
owners
A Close valve and valve
before adding oil and
ning engine.
Fill crankcase with
mark
on
cap
run
oil to full
dipstick (see Section 6.2).
6
Fuel Filter
7
FuelLine
Replace
Install
new
ac
manual.
line if cracked
new
filter.
or worn.
Wipe up any
spilled fuel.
Start engine, and check for fuel
leaks.
A Stop
engine,
tighten
connections as necessary,
and wipe up fuel.
Tools Needed:
~
L~ji
Ref. ST-801 188 / Ref. ST-801 221 / Ref. ST-I 78079-A / ST-800 395 / S-0842
OM-175 104
Page
15
6-5.
Adjusting Engine Speed
tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
After
as
2200–50rpm
follows:
Start engine and run until warm.
Turn Fine Adjust control to 10.
3700–50rpm
Speed Adjustment
Idle
Move Engine Control
Run/Idle position.
1
Throttle Solenoid
2
Mounting
3
Idle
switch to
Screws
Speed
Screw
mounting screws. Adjust
position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position.
Tighten mounting screws. Be sure
solenoid linkage works smoothly.
Loosen
solenoid
Turn
idle speed
adjustments.
screw
for fine
Weld/Power
Speed Adjustment
Move
Control switch to Run
Engine
position.
Speed
Adjustment Nut
4
Weld/Power
5
Lock Nut
Loosen lock nut. Turn
adjustment
engine runs at weld/power
speed. Tighten lock nut.
nut until
A
Stop engine.
Tools Needed:
~:=~z
1/4,3/8in
ST-801 209 / Ref. ST-801 188
OM-175 104
Page
16
6-6.
Overload Protection
A Stop engine.
1
Fuse Fl
(See
Parts
List)
Fl protects the generator excita
tion circuit. if Fl opens, there will
be no/low weld and auxiliary power
output.
2
Fuse F6
(See
Parts
List)
F6 protects the engine
harness. If F6 opens, the
does not crank.
wiring
engine
Replace any open fuses. Reinstall
panel before operating unit.
~7 If any fuse continues
contact
Factory
Seivice Agent.
to open,
Authorized
Tools Needed:
~
3/8 in
ST-801 226/ Ref. ST-801 221
6-7.
Inspecting
And
Cleaning Optional Spark
Arrestor
~dK~H~1 fi
A Stop engine
1
Spark
and let cool.
Arrestor Screen
Clean
and inspect screen. Re
place spark arrestor if screen wires
are broken or missing.
Tools Needed:
____
Z~
1/4 in
ST-sQl 206/ Ref. ST-801 221 / Ref. ST-172 782-A
OM-175 104
Page
17
6-8.
Troubleshooting
Yi~d*~i~
A.
Welding
Trouble
No weld output.
Remedy
Check control
settings.
Check weld connections.
Check fuse Fl and
Be
sure
Have
equipment
Factory
Check
Low weld output.
all
plug
High
Check control
Erratic weld output.
Use
replace
if open
check brushes,
when
starting
unit.
slip rings, and integrated rectifier SR2.
(see Section 6-6).
according
to
engine manual.
Authorized Service
Agent
check brushes and
slip rings.
settings.
adjust engine speed (see
Check control
Tighten
Agent
receptacles
adjust engine speed (see Section 6-5).
Factory
Check and
is disconnected from
settings.
Service air cleaner
weld output.
(see Section 6-6).
PLG6 connection.
Check control
Have
open
Authorized Service
Check fuse Fl and
Check and
replace if
Section
6-5).
settings.
and clean connections to electrode and
dry, properly-stored electrodes for SMAW
workpiece.
and GTAW.
Remove excessive coils from weld cables.
Tighten
and clean connections both inside and outside
Check and
Have
B.
Auxiliary
adjust engine speed (see
Section
Factory Authorized Service Agent
6-5).
check brushes and
slip rings.
Power
Trouble
No output at
welding generator.
auxiliary
power
Remedy
Reset circuit breakers
(see Sections
5-1 and
5-2).
receptacles.
Press
receptacle Reset
Check fuse Fl and
Check
Have
High
power output.
Low power output.
plug
Erratic power output.
Authorized Service
Agent
adjust engine speed (see
Check
Have
18
Adjust
control Ri
check brushes,
Section
slip rings, and integrated rectifier
6-5).
(see Section 6-6).
setting.
Check fuel level.
Check and
Page
replace if open (see Section 6-6).
Check fuse Fl and replace if open
Increase Fine
OM-175 104
(see Section 5-1).
PLG6 connection.
Factory
Check and
button
adjust engine speed (see Section 6-5).
receptacle wiring
Factory
and connections.
Authorized Service
Agent
check brushes and
slip rings.
SR2.
C.
Engine
Trouble
Engine
Remedy
Check fuse F6, and
will not crank.
Check
battery voltage.
Check
battery
Check
plug
Have
Engine
connections and
PLG4 and
Factory
if open
replace
(see Section 6-6).
tighten if necessary.
plug PLG8
Authonzed Service
connections.
Agent
check
Engine
Control switch S2.
Check fuel level.
will not start.
Check
battery voltage.
Check
battery
connections and
tighten
if necessary.
Check oil level. Check low oil pressure shutdown switch (see Section 3.4).
Have
Engine starts but stops when
Control switch returns to Run
Engine
position.
Factory
Authorized Service
Agent
Check oil level. Check low oil pressure shutdown switch
Check and refill crankcase with proper
Engine stopped during
operation.
check fuel shutoff solenoid FS1.
(see parts
list for
location).
viscosity oil for operating temperature,
if necessary.
Check fuel level.
normal
Check oil level. Check low oil pressure shutdown switch
Periodically recharge battery (approximately
every 3
(see Section 3-4).
months).
Replace battery.
Check
Have
Battery Discharges
between uses.
voltage regulator and
Factory
Clean
connections
Authorized Service
battery, terminals,
according
to
engine manual.
Agent check fuel shutoff
and posts with
baking
Periodically recharge battery (approximately
solenoid FS1.
soda and water solution; rinse with clear water.
every 3
months).
Replace battery.
Check
Engine
idles but does not
come
up to
Have
voltage regulator
Factory
and connections
Authorized Service
Agent
according
to
engine
manual.
check auto idle module PCi, and current transformer CT1.
~
weld
speed.
Unstable
or
sluggish engine speeds.
Readjust
throttle
linkage
if necessary. Check throttle solenoid TS1 for smooth
Tune-up engine according
Engine
does not return to idle
speed.
Remove weld and
Check throttle
to
auxiliary
linkage
engine
operation.
manual.
power loads.
for smooth,
non-binding operation.
Have Factory Authorized Service Agent check idle module PCi, current transformer CT1,
Control switch S2, and throttle solenoid TS1.
OM-175 104
Engine
Page
19
SECTION 7- ELECTRICAL DIAGRAM
(
~
____
~or)
~
II
I
I
II
I
:z~
~<m
~-<m ~<fl
~
II
~
H
II
II~~
I
IL
SB-180 690-A
Figure
OM-175 104
Page
20
7-1. Circuit
Diagram
For
Welding
Generator
NOTES
OM-175 104
Page
21
SECTION 8-PARTS LIST
F.-
~
to
c.J
C.,
Co
Co
D)
LI~
C.,
CJ
0)
to
CJ
(0
Il)
C.)
C,
C)
C.,
Cj
Co
ST-801 432-A
Figure
OM-175 104
Page
22
8-1. Main
Assembly
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
+159 907...
1
8-1. Main
Assembly
1
COVER, top
+169441...COVER,top
108 487... LABEL, warning: falling equipment
1
2
169 329...
3
3
4
.169 442...
159914...
168 640...
164928...
178497...
147 601
5
6
7
8
9
...
178498...
178 632
10
11
12
13
14
15
121 652...
173 088...
164 353...
173042...
165 271
TS1
180096...
Quantity
1
can cause
serious
1
injury
2
PANEL, side
PANEL, side
UPRIGHT, base
SEAL, tank fuel filler neck
SEAL, barrel 11.78 IDx .378thk
PANEL, rear lower
CAP, tank screw-on w/vent
TANK, fuel 8.5gaI (consisting of)
FITTING, stand pipe hose .250 x 7.325 Ig
FILTER KIT, fuel w/clamps
LABEL, engine maintenance
MUFFLER, exhaust engine w/heat shield
ENGINE, gas elec start (consisting of)
VALVE, oil drain 3/8-18NPTF
SOLENOID, 14VDC .53A (see engine parts list)
BRACKET~ mtg solenoid (see engine parts list)
TUNE-UP & FILTER KIT, (consisting of)
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
066 698
OIL FILTER
1
121 652
FILTER/CLAMPS, fuel
ELEMENT, air cleaner
AIR FILTER, wrapper
1
067 272
067 273
1
1
SPARK PLUG
GENERATOR
8-3...
Fig
182361... KIT, holddown battery
2
067 007
16
...24
18
168385...
19
+159917...
173921
168 037
082319...
172 669...
173 043...
165660...
165578...
176301
164 920...
159 906...
160 844
165817...
+159911..
...28
...29
Fig8-2..
SRi
....
iT
...36.... .D4
SR2
Fl
....
....
.01
CT1
.43.... .R2
RC4
PLG6
PLG4
RC6
....
....
1
STABILIZER
1
,
1
1
1
1
1
1
1
REACTOR
1
BRACKET, mtg stab/reactor
PAN, base
COVER, base
2
1
4
1
LABEL, warning general precautionary
PANEL, front lower
PANEL, front w/components
1
1
RECTIFIER, si 1 ph 300A 400PIV
LINK, jumper
BLOCK, stud connection 6 position
2
DIODE BOARD
1
035 704..
172731..
RECTIFIER, integ 40A 800V
1
HOLDER, fuse mintr
FUSE, mintr gI 25A 1 25V
CAPACITOR, elctlt 1 000uf 75VDC
CLAMP~ capacitor 2.500dia clip
TRANSFORMER, current sensing
RESISTOR, WW adj 225W 0-6 ohm
1
1
136810..
CONNECTOR & PINS
CONNECTOR & PINS
168844..
CONNECTOR, (see engine parts list)
CONNECTOR, rect 4 pin/skt rcpt
*169296..
116045..
ordering a component originally displaying
Optional 043 051 Stainless Steel kit.
*Recommended Spare Parts.
+When
1
LABEL, warning battery explosion can blind
DOOR, access battery
CABLE, bat pos (included w/engine)
BATTERY, stor 12V 43Ocrk 75rsv GP58 dry
CABLE, bat neg
CABLE, bat neg
BRACKET, mtg engine
BRACKET mtg generator
142503..
173734..
172661
135184..
176719..
177136..
179494..
165599..
....
1
a
precautionary label,
1
1
1
1
1
1
1
1
~1
1
the label should also be ordered.
Part of
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-175 104
Page
23
Item
No.
Part
No.
Dia.
Mkgs.
Figure
Si
162671
165602...
8
....
9
S3
Ri
165 487
PCi
S2
142 724
117243...
176606...
147939...
GFCI2,3
CB1,2
CB3,4
Quantity
Description
8-2.
Panel, Front w/Components (Fig 8-1 Item 44)
CIRCUIT BREAKER,
CIRCUIT BREAKER,
117501
093 996
1
SWITCH, polarity 5 position
NAMEPLATE, (order by model and serial number)
PANEL, front
SWITCH, selector 4 position
RHEOSTAT, WW 100W 10 ohm
MODULE, pull to idle 5 pin
SWITCH, ignition 4 position w/out handle
RECEPTACLE, str dx grd 2P3W 15A 125V
1
1
1
1
1
1
2
man
reset 1 P 40A 25OVAC
2
man
reset 1 P 20A 25OVAC
2
1
145247... METER, hour 12-24VDC
175010... CONTROL, push/pull
HM
1
1
LEVER, switch
119 014
1
R3,VR1 ....046819... SUPPRESSOR
099 255
15... Work, Elect
TERMINAL, pwr output neutral
RC1
164704... RECEPTACLE, str 3P4W 50A 1 25/250V
083030... STUD, brs .250-20 x 1.750
010915... WASHER, flat .250 ID brs
18
601836... NUT, .250-20 brs
...14....
.
2
.
1
1
3
3
1
159921... BEZEL
4
NUT, .375-27 nyl
...148956... HANDLE, switch
...147195...
...097924...
2
KNOB, pointer
1
4
2
1
5
.6
8
10
12
11
16
ST-800 816-A
Figure
8-2.
Panel, Front w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-175 104
Page
24
Item
No.
Part
No.
Description
Figure
1
013
..
..
+179500
..
....
159 909
..
5
....
053 390
....
6
....
160566
....
....
172 683
..
8
....
142156
..
9
....
3
...
4
7
....
160573
..
10....
125 548
..
11
005 614
....
..
21)
1
1
1
1
1
1
1
4
4
1
2
BRUSH w/SPRING
2
2
..
161 306
..
14....
047 879
..
15....
010910
..
...16....
o-iogog
17....
160 943
..
18....
143 220
....
..
8-1 Item
CAP, brushholder
BAR, retaining brushholder
WASHER,flat.4O6IDstI
NUT, .375-l6stl
ENDBELL, (consisting of)
0-RING, 2.859 ID x .139CS
*126 984
13....
12...
(Fig
LABEL, warning moving parts can cause serious injury
LABEL, warning engine fuel can cause fire
STATOR, generator
ROTOR, generator (consisting of)
BEARING, ball rdl sgl row 1.370 x 2.830 x .6
FAN, rotor
ADAPTER, engine
SCREW, .375-16x1.750hexhd
STUD, stl .375-16x17.125
HOLDER, brush elect
HOLDER, brush
367
165 818
....
2
8-3. Generator
Quantity
1
4
4
1
1
4
3
1
8
12
13
4
17
16
ST-Boo 798
Figure
-+-When
*
ordering
Recommended
a
component originally displaying
Spare
a
8-3. Generator
precautionary label,
the label should also be ordered.
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-175 104
Page
25