OHV220 Miller W FE Rev 0905 EH64 Welder Parts Manual
EH65 Welder Parts Manual manual pdf -FilePursuit
User Manual: EH64 Welder Parts Manual
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PARTS MANUAL Models EH64, 20.5 hp Engine EH65, 22.0 hp Engine Welder Applications (Onan Performer OHV220) PUB-EP220W Rev. 09/05 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2005 Robin America, Inc. -3- EH64, EH65 Performer OHV220 DESCRIPTION ROBIN Engine Specification ONAN Engine Specification MILLER HOBART MILLER BOBCAT MILLER TRAILBLAZER LINCOLN ELECTRIC MILLER BOBCAT MILLER TRAILBLAZER MILLER HOBART EH650DB2322 EH650DB2341 EH650DB2390 EH650DB2332 EH650DC2405 EH650DC2415 EH650DC2420 P220GIOHV-786A P220GIOHV-2252A P220GIOHV-2711A P220GIOHV-1145A NOTE: Horsepower is as follows; EH650DB - 20.5hp EH650DC - 22hp EH64, EH65 Performer OHV220 -4- GROUP INDEX Group Name Page CRANKCASE GROUP - EH64 ................................................................... 6 CRANKCASE GROUP - EH65 ................................................................. 10 CRANKSHAFT GROUP ........................................................................... 12 INTAKE and EXHAUST GROUP - EH64.................................................. 14 INTAKE and EXHAUST GROUP - EH65.................................................. 16 GOVERNOR GROUP .............................................................................. 18 BLOWER HOUSING GROUP ................................................................. 20 FUEL, LUBRICANT GROUP - EH64 ........................................................ 22 FUEL, LUBRICANT GROUP - EH65 ........................................................ 24 CARBURETOR - EH64 ............................................................................ 26 CARBURETOR - EH65 ............................................................................ 28 FLYWHEEL and STARTER GROUP - EH64 ............................................ 30 FLYWHEEL and STARTER GROUP - EH65 ............................................ 32 STARTER COMPONENTS ..................................................................... 34 APPENDIX A - Cylinder head & Valve guide change ............................... 36 APPENDIX B - Governor spring and rod positions................................... 37 V-TWIN SERVICE UPDATE WELDER APPLICATIONS ......................... 38 NO START FUEL CUT-OFF SOLENOID .................................................................... 39 STOP DIODE ........................................................................................... 40 WIRING HARNESS - Welder Applications ............................................... 41 SHUTDOWN RELAY - Welder Applications ............................................. 41 HARD START IGNITION COIL ........................................................................................ 44 HIGH ALTITUDE KITS.............................................................................. 45 FUEL PUMP ............................................................................................. 46 SPARK PLUG ........................................................................................... 47 REMOVAL & INSTALLATION PROCEDURES Hobart Champion, Miller Bobcat 225 and 250.......................................... 48 Miller Trailblazer 301G.............................................................................. 66 -5- EH64, EH65 Performer OHV220 SECTION 1 CRANKCASE GROUP - EH64, 20.5hp FIG. 100 19 47 46 47 46 48 25 P220GIOHV-2711A 44 EH64, EH65 Performer OHV220 -6- SECTION 1 REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 CRANKCASE GROUP - EH64, 20.5hp ROBIN PART NUMBER DESCRIPTION 263-10102-B1 CRANKCASE CP 263-15802-03 MAIN BEARING 263-15803-03 MAIN BEARING 263-15804-03 MAIN BEARING X31-00800-80 DOWEL PIN 142-55601-03 PIPE 263-15701-01 PIPE, PULSE 263-15911-A1 BLIND PLUG 044-00800-10 OIL SEAL 263-15901-03 UNION 045-01200-10 STEEL BALL 263-76001-A1 OIL PRESSURE SWITCH 263-11103-D1 MAIN BEARING COVER, AY 263-15802-03 MAIN BEARING 263-15803-03 MAIN BEARING 263-15804-03 MAIN BEARING 044-04200-30 OIL SEAL 263-45001-C1 GOVERNOR GEAR, CP 263-41901-03 GOVERNOR SLEEVE 263-46214-A3 WASHER 263-13001-21 CYLINDER HEAD 1, CP 263-14211-03 VALVE GUIDE 132-07AA0-50 INTAKE VALVE SEAL 010-50802-90 STUD, intake/exhaust X45-00600-10 STEEL BALL 263-16201-03 PLUG 263-13101-21 CYLINDER HEAD 2, CP 246-15501-01 ROCKER COVER, CP 246-16002-13 ROCKER COVER GASKET 263-15001-13 GASKET 1, CYLINDER HEAD 263-15101-13 GASKET 2, CYLINDER HEAD 263-16001-A3 MAIN BEARING COVER GASKET 263-16006-03 BREATHER PLATE GASKET 263-14301-03 BREATHER COVER 263-14401-01 BREATHER PLATE 263-18001-A3 RUBBER PIPE 263-68511-03 HOSE CLAMP X31-00600-20 DOWEL PIN 040-11400-30 PLUG 021-11400-20 GASKET X11-01000-30 FLANGE BOLT X11-00802-20 FLANGE BOLT X11-00600-30 FLANGE BOLT 263-46215-A3 THRUST BEARING 263-19001-A3 LIFTING HOOK -7- QTY 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 2 8 2 1 1 2 2 1 1 1 2 1 1 1 2 4 1 1 8 10 10 1 2 REMARKS ONAN PN 187-6000 STD 0.25mm Undersized 0.50mm Undersized 187-6003 187-6006 187-6007 187-6008 187-6170 STD 0.25mm Undersized 0.50mm Undersized 187-6172 187-6011 187-6012 187-6013 187-6014 187-6015 187-6016 187-6017 187-6018 187-6019 187-6020 187-6021 187-6022 187-6023 187-6024 187-6025 187-6026 187-6027 187-6028 187-6029 187-6030 187-6031 187-6032 187-6033 187-6034 187-6035 187-6036 187-6037 EH64, EH65 Performer OHV220 SECTION 1 CRANKCASE GROUP - EH64, 20.5hp FIG. 100 19 47 46 47 46 48 25 P220GIOHV-2711A 44 EH64, EH65 Performer OHV220 -8- SECTION 1 REF 43 44 CRANKCASE GROUP - EH64, 20.5hp ROBIN PART NUMBER DESCRIPTION 263-65005-A3 263-65006-A3 QTY OIL DRAIN VALVE ADAPTER 1 1 44 263-68101-B0 OIL DRAIN HOSE AY 1 46 47 48 056-51000-50 263-35341-03 X56-60800-40 CLIP RETAINER PLATE CLAMP, choke control 2 2 1 -9- REMARKS P220GIOHV-2252A EH650DB2341 P220GIOHV-786A EH650DB2322 P220GIOHV-2711A EH650DB2390 ONAN PN 504-0186 187-6173 187-6173 From S/N 1015769 EH64, EH65 Performer OHV220 SECTION 1 CRANKCASE GROUP - EH65, 22.0hp FIG. 100 49 47 46 46 47 45 45 45 50 50 42 9 44 43 EH650DC2415 44 EH64, EH65 Performer OHV220 - 10 - SECTION 1 REF 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44 45 46 47 49 50 CRANKCASE GROUP - EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 263-10112-A1 263-15802-03 X31-00800-80 142-55601-03 263-15701-01 263-15911-A1 044-00800-10 263-76001-A1 263-11103-E1 263-15802-03 044-04200-30 263-45001-C1 263-41901-03 263-46215-A3 263-46214-A3 263-13211-A1 010-50802-90 132-07AA0-50 263-13311-A1 263-15502-A3 263-15501-A3 263-16101-A3 263-15021-11 263-15121-01 263-16002-A3 263-16006-03 263-14301-03 280-14401-A1 280-19001-A3 263-18003-03 263-68511-03 X31-00600-20 X40-11400-30 021-11400-20 X11-01000-70 X11-00802-20 X11-00600-30 X11-00601-01 263-15901-03 263-65005-A3 263-65006-A3 263-68101-B1 263-14211-03 056-51000-50 263-35341-03 280-63602-A1 X45-00600-10 QTY CRANKCASE MAIN BEARING DOWEL PIN PIPE PIPE, PULSE BLIND PLUG OIL SEAL OIL PRESSURE SWITCH MAIN BEARING COVER BALL BEARING OIL SEAL GOVERNOR GEAR GOVERNOR SLEEVE THRUST BEARING WASHER CYLINDER HEAD 1 STUD SEAL, INTAKE VALVE CYLINDER HEAD 2 ROCKER COVER w/ oil fill ROCKER COVER GASKET, ROCKER COVER GASKET 1, CYLINDER HEAD GASKET 2, CYLINDER HEAD GASKET, MAIN BEARING COVER GASKET, BREATHER PLATE BREATHER COVER BREATHER PLATE HOOK RUBBER PIPE HOSE CLAMP DOWEL PIN PLUG GASKET FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT UNION OIL DRAIN VALVE ADAPTER OIL DRAIN HOSE VALVE GUIDE CLIP RETAINER PLATE OIL FILL CAP STEEL BALL - 11 - 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1 8 2 1 1 1 2 1 1 1 2 1 1 2 1 2 4 1 2 8 10 2 8 1 1 1 1 4 4 4 1 2 REMARKS ONAN PN STD 187-6003 187-6006 187-6170 187-6172 187-6011 187-6012 187-6016 187-6015 187-6024 187-6025 187-6026 187-6028 187-6029 187-6030 187-6031 187-6032 187-6033 187-6034 187-6035 EH650DC2405, DC2420 EH650DC2415 187-6007 504-0186 187-6173 187-6014 EH64, EH65 Performer OHV220 SECTION 2 CRANKSHAFT GROUP - EH64, 20.5hp & EH65, 22.0hp FIG. 200 EH64, EH65 Performer OHV220 - 12 - SECTION 2 REF 1 2 2 3 3 4 5 6 7 8 8 8 8 9 10 11 12 CRANKSHAFT GROUP- EH64, 20.5hp & EH65, 22.0hp ROBIN PART NUMBER 263-21301-21 263-21501-C1 263-22501-00 263-22502-00 263-22601-00 246-23001-13 001-05084-00 263-23411-A3 263-23412-A3 263-23413-A3 263-23301-03 263-23501-07 263-23502-07 263-23503-07 056-52100-20 263-25011-A3 263-25012-A3 263-25013-A3 263-25014-A3 002-18180-00 003-10180-00 003-20180-00 005-32054-01 DESCRIPTION CRANKSHAFT CP CRANKSHAFT CP CONNECTING ROD CONNECTING ROD CONNECTING ROD CONNECTING ROD BOLT CONNECTING ROD BOLT PISTON PISTON PISTON PISTON PIN PISTON RING SET PISTON RING SET PISTON RING SET RETAINING CLIP SPACER SPACER SPACER SPACER NUT WASHER SPRING WASHER WOODRUFF KEY - 13 - QTY 1 1 2 2 2 4 4 2 2 2 2 2 2 2 4 1 1 1 1 1 1 1 1 REMARKS ONAN PN Threaded, Miller - Hobart 187-6039 Taper, Lincoln STD - EH64 187-6040 Undersized 0.25mm - EH64 STD - EH65 - Miller Hobart STD- EH64 187-6041 STD- EH65 STD Oversized 0.25mm Oversized 0.50mm 187-6043 STD 187-6044 Oversized 0.25mm Oversized 0.50mm 187-6045 T=0.6 T=0.8 187-6046 T=1.0 187-6047 T=1.2 187-6048 187-6049 EH64 187-6050 EH64 187-6051 187-6052 EH64, EH65 Performer OHV220 SECTION 3 INTAKE and EXHAUST GROUP - EH64, 20.5hp FIG. 300 19 22 22 EH64, EH65 Performer OHV220 - 14 - SECTION 3 REF 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 INTAKE and EXHAUST GROUP - EH64, 20.5hp ROBIN PART NUMBER 263-33001-03 263-31701-13 263-33301-A3 263-33401-03 263-33502-13 246-33611-03 246-35501-03 246-33711-13 239-35001-03 263-35311-01 246-36101-10 014-90800-21 017-00800-90 263-35503-A3 002-38080-00 263-32610-A1 263-32620-01 263-32630-03 263-32640-01 X10-10500-10 263-35201-A1 DESCRIPTION INTAKE MANIFOLD CAMSHAFT TAPPET INTAKE VALVE EXHAUST VALVE VALVE SPRING VALVE COLLET SPRING RETAINER ROCKER SHAFT PUSH ROD ROCKER ARM AY ADJUSTING SCREW NUT MANIFOLD GASKET FLANGE NUT CLEANER ELEMENT CLEANER BASE CLEANER COVER WING NUT BOLT GASKET, EXHAUST - 15 - QTY 1 1 4 2 2 4 8 4 2 4 4 4 4 2 4 1 1 1 1 3 2 REMARKS ONAN PN 187-6053 187-6055 187-6057 2 Per Valve 187-6059 187-6060 187-6061 135.5mm 187-6063 187-6064 187-6065 187-6066 187-6067 187-6068 187-6069 187-6070 187-6071 EH64, EH65 Performer OHV220 SECTION 3 INTAKE and EXHAUST GROUP - EH65, 22.0hp FIG. 300 24 EH64, EH65 Performer OHV220 - 16 - SECTION 3 REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 INTAKE and EXHAUST GROUP - EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 280-33001-C3 INTAKE MANIFOLD 280-31701-13 CAMSHAFT 263-33301-A3 TAPPET 263-33401-03 INTAKE VALVE 263-33502-13 EXHAUST VALVE 246-33611-03 VALVE SPRING 246-35501-03 COLLET VALVE 246-33711-13 SPRING RETAINER 263-35321-B1 PUSH ROD 267-36101-13 ROCKER ARM 261-35801-13 BOLT, PIVOT 267-35701-03 PIVOT 017-00601-10 NUT 263-37001-A3 GUIDE PLATE 263-35503-A3 GASKET, INTAKE MANIFOLD 280-32601-A0 AIR CLEANER AY 263-32610-A1 CLEANER ELEMENT 280-32620-A1 CLEANER BASE 263-32630-03 CLEANER COVER 263-32640-01 WING NUT 263-95111-A3 LABEL, ONAN BY ROBIN 002-38080-00 FLANGE NUT X11-00600-20 FLANGE BOLT 270-35201-01 GASKET - 17 - QTY 1 1 4 2 2 4 8 4 4 4 4 4 4 2 2 1 1 1 1 1 1 4 3 2 REMARKS ONAN PN 187-6055 187-6057 2 per valve 187-6059 187-6060 138.5mm 187-6066 187-6068 187-6070 187-6071 187-6067 EH64, EH65 Performer OHV220 SECTION 4 GOVERNOR GROUP- EH64, 20.5hp & EH65, 22.0hp FIG. 400 22 14 17 22 7 EH64, EH65 Performer OHV220 - 18 - SECTION 4 REF 1 2 3 4 6 6 7 8 GOVERNOR GROUP- EH64, 20.5hp & EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 263-46021-B3 CHOKE LEVER 263-46011-A3 CHOKE CONTROL ROD 261-45201-03 RETURN SPRING 226-43101-01 LINK PIVOT 263-42301-B3 GOVERNOR LEVER 263-46021-B3 CHOKE LEVER 263-42201-A3 GOVERNOR SHAFT 263-42507-03 GOVERNOR SPRING, black QTY 1 1 1 1 1 1 1 1 8 263-42509-A3 GOVERNOR SPRING, blue 1 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 263-42509-A3 263-42701-A3 263-42801-03 263-43311-A3 263-45021-A2 261-43901-03 005-11060-01 001-14063-00 X18-60600-20 X11-00600-20 X11-50500-20 002-27050-00 002-38060-00 001-17052-00 003-10080-00 X23-00801-50 GOVERNOR SPRING, blue GOVERNOR ROD ROD SPRING SPEED CONTROL LEVER SPEED CONTROL BRACKET CLAMP SNAP PIN BOLT and WASHER AY NUT FLANGE BOLT BOLT and WASHER AY NUT FLANGE NUT BOLT and WASHER AY WASHER SPACER 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 - 19 - REMARKS ONAN PN 187-6075 187-6076 187-6077 187-6175 EH650DC2420 187-6079 P220GIOHV-786A EH650DB2322 P220GIOHV-1145A EH650DB2332 P220GIOHV-2252A EH650DB2341 P220GIOHV-2711A EH650DB2390 EH65 187-6081 187-6082 187-6083 187-6084 187-6085 187-6086 187-6087 187-6088 187-6089 187-6090 187-6091 187-6092 187-6093 EH64, EH65 Performer OHV220 SECTION 5 BLOWER HOUSING GROUP- EH64, 20.5hp & EH65, 22.0hp FIG. 500 7 13 13 13 4 6 6 6 14 5 14 12 6 EH64, EH65 Performer OHV220 - 20 - SECTION 5 REF 1 2 3 4 5 6 7 8 9 11 12 13 14 BLOWER HOUSING GROUP- EH64, 20.5hp & EH65, 22.0hp ROBIN PART NUMBER 263-51101-B2 263-51121-B2 263-52603-A1 263-52612-A1 263-52703-B1 263-52704-A1 263-52801-03 263-52911-B2 263-52912-A2 X11-00600-20 X11-00601-40 001-14061-60 263-92001-03 263-54101-02 263-95112-A3 X11-00600-30 X11-00600-10 DESCRIPTION BLOWER HOUSING BLOWER HOUSING CYLINDER BAFFLE 1 CYLINDER BAFFLE 1 CYLINDER BAFFLE 2 CYLINDER BAFFLE 2 CYLINDER BAFFLE 3 CYLINDER BAFFLE 4, UNIT CYLINDER BAFFLE 4 FLANGE BOLT FLANGE BOLT BOLT and WASHER AY LABEL, warning COOLING BLOWER UNIT LABEL, trademark FLANGE BOLT FLANGE BOLT - 21 - QTY 1 1 1 1 1 1 1 1 1 5 2 4 1 1 1 4 2 REMARKS EH64 EH65 EH64 EH65 EH64 EH65 ONAN PN 187-6094 187-6097 EH64 EH65 EH64 EH64 187-6099 187-6100 187-6102 187-6073 EH64, EH65 Performer OHV220 SECTION 6 FUEL and LUBRICANT GROUP- EH64, 20.5hp FIG. 600 38 15 32 36 31 12 30 22 EH64, EH65 Performer OHV220 - 22 - SECTION 6 REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 29 30 31 32 33 34 35 36 37 38 FUEL and LUBRICANT GROUP - EH64, 20.5hp ROBIN PART NUMBER DESCRIPTION 263-63901-03 INNER ROTOR 263-63902-03 OUTER ROTOR 263-64302-02 OIL PUMP FILTER UNIT 263-64001-B1 OIL PUMP COVER, CP 044-03501-70 OIL SEAL X24-89000-30 O RING 263-65001-13 OIL RELIEF PLUG 003-70140-00 ALUMINUM GASKET 248-65601-03 RELIEF VALVE SPRING 006-90308-00 STEEL BALL 248-65801-00 OIL FILTER AY 263-63604-11 OIL GAUGE CP 246-63606-09 OIL FILL CAP 021-31800-10 GASKET 263-68006-B3 RUBBER PIPE 263-68501-03 HOSE CLAMP 263-62431-00 CARBURETOR 263-66201-A3 CARBURETOR GASKET 280-62201-00 FUEL PUMP 263-65003-A1 FUEL PUMP BRACKET 263-68009-B3 RUBBER PIPE 024-01000-10 OIL GAUGE O RING 263-65011-A3 BOLT X11-00801-10 FLANGE BOLT X11-00601-40 FLANGE BOLT 263-65012-A3 FUEL FILTER 263-65102-A3 OIL FILL TUBE 085-10301-10 RUBBER PIPE 206-75501-01 CLAMP CP 263-63621-01 OIL GAUGE TUBE 021-81800-10 OIL FILL TUBE GASKET 056-60001-70 STRAP CLAMP 002-18180-00 HEX NUT X11-00600-20 FLANGE BOLT X11-00600-90 FLANGE BOLT 263-67102-A3 SPACER - 23 - QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 6 1 1 1 1 1 2 1 2 4 1 1 1 2 1 1 2 1 5 2 2 REMARKS ONAN PN 187-6103 187-6104 187-6108 187-6109 187-6110 187-6111 187-6112 187-6191 187-6192 187-6113 187-6114 NEW - High performance 187-6115 187-6116 187-6196 187-6194 187-6117 187-6118 187-6119 187-6199 187-6121 187-6198 187-6200 187-6201 187-6218 815-0753 EH64, EH65 Performer OHV220 SECTION 6 FUEL and LUBRICANT GROUP- EH65, 22.0hp FIG. 600 38 EH64, EH65 Performer OHV220 - 24 - SECTION 6 REF 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 FUEL and LUBRICANT GROUP - EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 263-63901-03 INNER ROTOR 263-63902-03 OUTER ROTOR 263-64302-02 OIL PUMP FILTER UNIT 263-64001-B1 OIL PUMP COVER 044-03501-70 OIL SEAL X24-89003-30 O RING 263-65001-13 OIL RELIEF PLUG 003-70140-00 ALUMINUM GASKET 248-65601-03 RELIEF VALVE SPRING 006-90308-00 STEEL BALL 263-63604-11 OIL GAUGE CP 280-63602-A1 OIL FILL CAP 263-63622-01 GAUGE 024-01000-10 O RING 263-62606-B1 FUEL PIPE 263-68006-B3 RUBBER PIPE 263-68501-03 HOSE CLAMP 263-62391-00 CARBURETOR 085-10301-10 RUBBER PIPE 206-75501-01 CLAMP 263-66201-A3 GASKET, CARBURETOR 280-62201-00 FUEL PUMP 251-62251-08 DIAPHRAGM GASKET SET 251-62250-08 SCREW 263-65002-A3 BRACKET, FUEL PUMP 263-62653-B1 PULSE PIPE 263-68008-B3 RUBBER PIPE 263-68501-03 HOSE CLAMP 263-65012-A3 FUEL FILTER 263-68007-B3 RUBBER PIPE 263-68501-03 HOSE CLAMP 263-65011-A3 FLANGE BOLT X11-00801-10 FLANGE BOLT X11-00600-30 FLANGE BOLT X11-00600-20 FLANGE BOLT 248-65801-00 OIL FILTER AY - 25 - QTY 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 2 1 1 1 4 1 1 1 2 1 1 2 1 2 4 5 1 REMARKS ONAN PN 187-6103 187-6104 187-6108 187-6109 187-6110 187-6111 187-6112 187-6191 187-6194 187-6113 187-6121 187-6114 NEW- High Performance 187-6115 187-6119 187-6117 815-0753 EH64, EH65 Performer OHV220 SECTION 6 FUEL and LUBRICANT GROUP - EH64, 20.5hp FIG. 610 17 EH64, EH65 Performer OHV220 - 26 - SECTION 6 REF 17 -1 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 FUEL and LUBRICANT GROUP - EH64, 20.5hp ROBIN PART NUMBER DESCRIPTION 263-62431-00 CARBURETOR AY 280-62545-08 GASKET,AIR HORN 263-62524-08 LEVER ASSY,CHOKE 258-62551-08 RING,CHOKE LEVER 263-62445-08 SPRING,CHOKE 280-62550-08 COLLAR,CHOKE 258-62554-08 FILTER,CHOKE SHAFT 263-62520-08 SHAFT ASSY,CHOKE 258-62525-08 VALVE,CHOKE 258-62555-08 SCREW,VALVE SET 258-62450-08 SCREW,AIR HORN SET 226-62501-08 VALVE,FLOAT 280-62505-08 FLOAT 258-62515-08 PIN,FLOAT 258-62556-08 SCREW,FLOAT PIN SET 263-62400-08 JET,MAIN 258-62557-18 SOLENOID VALVE ASSY 258-62546-08 GASKET,SOLENOID 258-62420-08 JET,SLOW 258-62445-08 SPRING,ADJUST SCREW 263-62451-08 SCREW,THRO.ADJUST 261-62435-08 NEEDLE, idle adjust 263-62531-08 SHAFT ASSY,THROTTLE 226-62580-08 FILTER,AIR 258-62570-08 COLLAR,THRO.SHAFT 263-62535-08 VALVE,THROTTLE 261-62352-08 SCREW,VALVE SET 258-62560-08 PLUG,EXPANSION 258-62566-08 CLAMP,SOLENOID 263-62552-08 PLUG 215-62353-08 SCREW,DRAIN 215-62446-08 SPRING,DRAIN SCREW 263-62560-08 “O”RING,AIR HORN 263-62555-08 GASKET 261-62358-08 PLUG, anti tamper - 27 - QTY 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 REMARKS ONAN PN EH64, EH65 Performer OHV220 SECTION 6 FUEL and LUBRICANT GROUP - EH65, 22.0hp FIG. 610 17 EH64, EH65 Performer OHV220 - 28 - SECTION 6 REF 17 -1 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 FUEL and LUBRICANT GROUP - EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 263-62391-00 CARBURETOR AY 280-62545-08 GASKET,AIR HORN 263-62524-08 LEVER ASSY,CHOKE 258-62551-08 RING,CHOKE LEVER 263-62445-08 SPRING,CHOKE 280-62550-08 COLLAR,CHOKE 258-62554-08 FILTER,CHOKE SHAFT 263-62520-08 SHAFT ASSY,CHOKE 258-62525-08 VALVE,CHOKE 258-62555-08 SCREW,VALVE SET 258-62450-08 SCREW,AIR HORN SET 226-62501-08 VALVE,FLOAT 280-62505-08 FLOAT 258-62515-08 PIN,FLOAT 258-62556-08 SCREW,FLOAT PIN SET 263-62400-08 JET,MAIN 263-62556-08 SOLENOID VALVE ASSY 258-62546-08 GASKET,SOLENOID 258-62420-08 JET,SLOW 258-62445-08 SPRING,ADJUST SCREW 263-62451-08 SCREW,THRO.ADJUST 261-62435-08 NEEDLE, idle adjust 263-62531-08 SHAFT ASSY,THROTTLE 226-62580-08 FILTER,AIR 258-62570-08 COLLAR,THRO.SHAFT 263-62535-08 VALVE,THROTTLE 261-62352-08 SCREW,VALVE SET 258-62560-08 PLUG,EXPANSION 258-62566-08 CLAMP,SOLENOID 263-62552-08 PLUG 215-62353-08 SCREW,DRAIN 215-62446-08 SPRING,DRAIN SCREW 263-62560-08 “O”RING,AIR HORN 263-62555-08 GASKET 261-62358-08 PLUG, anti tamper - 29 - QTY 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 REMARKS ONAN PN EH64, EH65 Performer OHV220 SECTION 7 FLYWHEEL and STARTER GROUP - EH64, 20.5hp FIG. 700 33 32 26 28 26 20 22 20-1 20-2 EH64, EH65 Performer OHV220 - 30 - SECTION 7 REF 1 2 3 FLYWHEEL and STARTER GROUP - EH64, 20.5hp ROBIN PART NUMBER DESCRIPTION 263-77202-11 FLYWHEEL CP 263-78202-11 IGNITION COIL CP 263-79411-A1 CHARGE COIL QTY 1 2 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 20-1 20-2 21 22 23 24 25 26 28 263-71001-03 263-70502-A0 263-71901-01 KU3-11052-21 X65-01407-30 X65-51000-10 X65-91000-10 001-14062-50 X13-10500-40 X11-00801-00 X11-00600-10 X56-30000-80 X11-00601-40 206-75501-01 263-73116-A1 WELDER FUSE EH65A0256 263-72003-A1 263-73117-A1 010-00500-60 263-75403-B1 263-75302-A1 263-79902-A3 056-61500-20 RING GEAR STARTING MOTOR REGULATOR STOP DIODE SPARK PLUG SPARK PLUG CAP PLUG TERMINAL BOLT and WASHER SCREW and WASHER FLANGE BOLT FLANGE BOLT WIRE BAND FLANGE BOLT CLAMP HARNESS, ENGINE TO WELDER FUSE DIODE AY SHUTDOWN RELAY HARNESS, RELAY TO ENGINE RELAY BOLT SOLENOID BRACKET SOLENOID SCREW CLAMP, HARNESS 1 1 1 1 2 2 2 4 4 2 1 3 2 2 1 1 1 1 1 1 1 1 2 1 30 31 32 33 002-38080-00 X11-00600-10 001-13082-00 X31-80300-20 NUT FLANGE BOLT BOLT and WASHER ROLL PIN 1 2 1 1 - 31 - REMARKS ONAN PN P220GIOHV-1145A EH650DB2332 187-6159 187-6184 187-6160 NGK BPR4EY 187-6163 187-6166 187-6167 Incl 20-1, 20-2 BUSS AGX 30amp 187-6118 187-6169 187-6187 187-6188 187-6189 187-6180 187-6181 187-6182 P220GIOHV-2252A EH650DB2341 EH64, EH65 Performer OHV220 SECTION 7 FLYWHEEL and STARTER GROUP - EH65, 22.0hp FIG. 700 33 26 32 26 20 20-1 20-2 EH64, EH65 Performer OHV220 - 32 - SECTION 7 REF 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 20-1 20-2 24 25 26 30 32 33 FLYWHEEL and STARTER GROUP - EH65, 22.0hp ROBIN PART NUMBER 263-77202-01 263-78202-11 263-79411-A1 263-71001-03 263-70502-A0 263-71901-01 KU3-11052-21 X65-01407-30 X65-51000-10 X65-91000-10 001-14062-50 X13-10500-40 X11-00801-00 X11-00600-10 X56-30000-80 X11-00601-40 206-75501-01 263-73118-A1 EH65A0256 263-75404-A1 263-75302-A1 263-79902-A3 002-38080-00 001-13082-00 X31-80300-20 DESCRIPTION FLYWHEEL CP IGNITION COIL CP CHARGE COIL QTY 1 2 1 RING GEAR STARTING MOTOR REGULATOR STOP DIODE SPARK PLUG SPARK PLUG CAP PLUG TERMINAL BOLT and WASHER SCREW and WASHER FLANGE BOLT FLANGE BOLT WIRE BAND FLANGE BOLT CLAMP HARNESS, ENGINE TO WELDER FUSE DIODE AY SOLENOID BRACKET SOLENOID SCREW NUT BOLT and WASHER ROLL PIN - 33 - 1 1 1 1 2 2 2 4 4 2 1 4 2 1 1 1 1 1 1 2 1 1 1 REMARKS ONAN PN P220GIOHV-1145A EH650DB2332 187-6159 187-6184 187-6160 NGK BPR4EY 187-6163 187-6166 187-6167 Incl 20-1, 20-2 BUSS AGX 30amp 187-6118 187-6169 187-6187 187-6181 187-6182 EH64, EH65 Performer OHV220 SECTION 8 STARTER COMPONENTS- EH64, 20.5hp & EH65, 22.0hp FIG. 800 EH64, EH65 Performer OHV220 - 34 - SECTION 8 REF 1 2 3 4 5 6 7 8 STARTER COMPONENTS- EH64, 20.5hp & EH65, 22.0hp ROBIN PART NUMBER DESCRIPTION 263-70502-A0 STARTING MOTOR AY 263-70550-08 THRUST WASHER KIT 210-70534-08 PINION STOPPER SET 263-70505-08 REAR COVER 255-70531-08 BRUSH HOLDER 255-70521-08 PINION STOPPER SET 243-70525-08 SHIFT LEVER KIT 263-70515-08 MAGNETIC SWITCH - 35 - QTY 1 1 1 1 1 1 1 1 REMARKS ONAN PN 187-6184 187-6208 187-6202 187-6203 187-6204 187-6205 187-6206 187-6207 EH64, EH65 Performer OHV220 APPENDIX A EH64, EH65 Performer OHV220 - 36 - APPENDIX B - 37 - EH64, EH65 Performer OHV220 Robin Subaru - V-Twin Service Update - Welder Applications Forward The following three conditions must be fulfilled for satisfactory engine start 1. The cylinder filled with a proper fuel-air mixture. 2. Good compression in the cylinder. 3. Good spark, properly timed, to ignite the mixture. The engine cannot be started unless these three conditions are met. There are also other factors which make engine start difficult, e.g., a heavy load on the engine when it is about to start at low speed, and a high back pressure due to a long exhaust pipe. The most common causes of engine troubles and solutions are given throughout the following pages. EH64, EH65 Performer OHV220 - 38 - Robin Subaru - V-Twin Service Update - Welder Applications FUEL CUT-OFF SOLENOID The fuel solenoid controls the flow of fuel from the float chamber into the main jet. When the engine is not running, the plunger will remain extended. During starting and operation, 12 volts DC is applied to the solenoid and the plunger is retracted. Fuel is then allowed to flow to the main jet. Fig. 2 - Tap the solenoid 2. Loosen the solenoid a few turns without removing the solenoid from the carburetor. This will extract the plunger from the main jet. Re-tighten the solenoid and test. Fig. 1 - Carburetor cross section If solenoid does not function, proceed to step 3. PROBLEM No Start. Engine cranks but does not start. Stale fuel can cause gum deposits around the plunger in the solenoid not allowing the plunger to retract during starting. This stops the fuel supply to the main jet causing the engine not to start. Verify the following: • Spark at the spark plug - if dry see remedies • Oil - Check oil level • Fuel - Check fuel supply • Crank Speed • Battery Fig. 3 - Clean the solenoid plunger CORRECTIVE ACTION Please follow in this order as necessary. 1. Tapping lightly on the side of the solenoid. This may free the plunger from any gum build up. 3. Remove solenoid from carburetor. Spray carburetor cleaner into the plunger end, as well as in the carburetor body. See Fig. 4. Gently manipulate plunger to loosen gum deposits. Test the solenoid operation by turning the start switch to the “Start” position. The solenoid plunger Turn the start switch to the “Start” position to energize the solenoid. The solenoid will make a “clicking” will retract when 12V DC power is applied. Note: solenoid will need to be grounded when power is sound as the 12V DC power is applied. If no sound is heard, proceed to step number two. See figure 2. applied. If solenoid does not function after cleaning, proceed to step 4. - 39 - EH64, EH65 Performer OHV220 Robin Subaru - V-Twin Service Update - Welder Applications ! WARNING ! STOP DIODE Remove solenoid only on cold engine. When solenoid is removed from carburetor, any fuel in the float chamber will drain out. The stop diode serves to isolate each ignition coil while allowing one grounding lead to be used to ground both coils to stop the engine. It is located under the shroud, above the starter motor. Fig. 4 - Stop diode mounted on engine PROBLEM Fig. 4 - Clean the carburetor solenoid hole and main jet Engine cranks but does not start. The condition could be caused by a defective stop diode. 4. If cleaning does not restore the solenoid operation, replace fuel solenoid (part no. 263-62556-08). To replace the solenoid, cut red wire close to the solenoid. Install the new solenoid and reconnect the wires using a crimp connector. CORRECTIVE ACTION • Measure the continuity between the wires. Black (-) needle A B B 8 C Continuity C Continuity 8 (Continuity = Closed Circuit / 8 8 8 A Red (+) needle C = Open Circuit) B A Fig. 5 - Cut the wire close to the solenoid when replacing • Replace the stop diode if the actual value differs from the rated value. EH64, EH65 Performer OHV220 - 40 - Robin Subaru - V-Twin Service Update - Welder Applications WIRING HARNESS SHUTDOWN RELAY For Miller Electric and Hobart Welder Applications Only For Miller Electric and Hobart Welder Applications Only - EH64, 20.5hp The wiring harness on the Onan/Robin OHV engines for Miller Electric and Hobart, includes a diode and a Buss AGX 30 amp fuse. The purpose of the fuse is to protect the wiring harness should a short occur. Note: it is important that the correct fuse length (15/ 16 in.) be installed in the fuse holder. The relay contacts are wired between the Stop Diode and Ground. The relay contacts are normally closed and ground the ignition coils (stop the engine). Please refer to the relay diagram and the wiring diagram. The purpose of the bypass diode is to prevent feedback to the starter solenoid. If the diode is “shorted”, the engine continues to crank after the start stop switch is released from the start position. If the diode is “open” the engine will crank, but will not start. An open diode will not allow the shutdown relay to energize and remove the ground from the ignition coils. The harness is located on the oil filter side of the engine. PROBLEM Engine will not crank or start. Could be caused by either a blown fuse or faulty diode. The relay has two functions. During engine running the relay coil is energized by a 12V DC power signal controlled by the oil pressure switch. This removes the ignition ground and allows the engine to operate. If the oil pressure drops below the minimum pressure, the oil pressure switch will switch the power off the relay coil and the ignition coils will be grounded to turn off the engine. The relay also has an important function during engine startup. At startup, the oil pressure will initially be low. During start-up the welder control system will provide 12V DC to the relay coil to remove the ignition coil ground and to by-pass the oil pressure switch. This allows the engine to start quickly. CORRECTIVE ACTION • Split the harness open with your hands to reveal the diode and the fuse. Replace the diode, part # EH65A0256. PROBLEM 1. The engine will crank, but will not start. 2. The engine does not shut down immediately when the engine is turned off. SYMPTOMS 1. Fuel to the spark plugs (plug wet) - OK 2. No spark 3. The Stop Diode tests good - 41 - EH64, EH65 Performer OHV220 Robin Subaru - V-Twin Service Update - Welder Applications Note: If the engine wiring harness is disconnected from the welder, the engine will not start. Among other functions, the welder control system provides power to the relay during start-up to remove the ignition coil ground. TEST PROCEDURES Step 1 Remove the relay and unplug the wire connector. Check for continuity across the normally closed contacts, spade connectors #30 and #87A. If there is no continuity, the relay should be replaced. Step 3 Apply 9 - 12V DC across the relay coil on spade connectors #85 and #86 (brass colored). Check for continuity across the normally closed contacts, spade connectors #30 and #87A. With the relay coil energized, there should be no continuity (open circuit). If there is continuity while the coil is powered, the relay should be replaced. Relay Diagram and Schematic Step 2 Apply 9 - 12V DC across the relay coil on spade connectors #85 and #86 (brass colored). A “clicking” sound should be heard as the power is applied and removed. Proceed to step 3. Wiring Diagram For Miller Electric and Hobart Welder Applications Only Engine Specification Numbers: EH650DB2332 EH650DB2341 EH650DB2390 EH64, EH65 Performer OHV220 - 42 - Robin Subaru - V-Twin Service Update - Welder Applications Wiring Diagram For Miller Electric and Hobart Welder Applications Only Engine Specification Numbers: EH650DC2405 EH650DC2415 EH650DC2420 - 43 - EH64, EH65 Performer OHV220 Robin Subaru - V-Twin Service Update - Welder Applications IGNITION COILS - EH64, 20.5hp The ignition coils have gone through two changes. The first being a vendor change. The second, to improve starting. Figure 1 shows the original coil. These coils perform well and only be replaced upon coil failure. Figure 2 shows the coil after the vendor change. If this coil is being used, we suggest that you update the coil to the one shown in figure 3. Figure 3 shows the newest coil. This last change was made to improve startability. Please note the White dot identifies the current design from the previous coil (fig. 2). Bolt P/N 001-14063-00 Fig 1 - Original Ignition Coil - Do Not Replace PROBLEM Hard starting, hard starting in cold temperature. CORRECTIVE ACTION 1. Check the ignition coil. If the coils match the coil shown in figure 2, replace both coils and order (2) plug terminals #X65-91000-10. File a warranty claim. 2. Check the coil gap to the flywheel magnet. The ignition coil air gap clearance is 0.3 mm or (0.012 - 0.015 in). This measurement is done with a thickness gauge between the ignition coils and flywheel. Tighten the left bolt first, then the right bolt. Rotate the flywheel and recheck the clearance. Bolt P/N 001-14062-50 Fig 2 - New Design - After Vendor Change Bolt P/N 001-14062-50 Air Gap: 0.03mm (.012 -.015 in) Torque: 5.1 - 6.5 ft-lb. EH64, EH65 Performer OHV220 Fig 3 - Revised New Design - White Paint Mark - 44 - Robin Subaru - V-Twin Service Update - Welder Applications NOTE: DO NOT OVERTIGHTEN THE JET OR THE Installation of a high altitude kit will help increase en- HEAD WILL STRIP gine performance and decrease exhaust emissions at higher altitudes. HIGH ALTITUDE KITS PROBLEM For operation of engine above 5,000 ft (1,500 meters), to avoid poor engine performance. CORRECTIVE ACTION Install a High Altitude kit. Please follow in this order. 1. Remove carburetor from engine. Unscrew the solenoid valve from the carburetor with a 19mm metric wrench. 4. Replace solenoid valve, and reinstall carburetor on the engine. Once the jets have been changed, the high altitude label should be affixed somewhere noticeable on the engine (shroud or air cleaner cover) and the owner’s manual addendum is required to be given to the engine owner. 2. Unscrew the standard jet from carburetor using a flat head screw driver. An engine which has been converted for high altitude use, cannot be run at lower altitudes. A high altitude converted engine running at lower altitude will run lean causing the engine to overheat leading to internal damage. The affixed high altitude label identifies which engines have been converted, and should be taken off when the engine is restored to its original factory specification. Kit numbers: 92630024 - Used on EH64, 20.5hp EH65, 22.0hp 92630025 - Used on EH72 25.0hp Kits include the following: 1. Instructions and BOM 2. Warning label 3. Owner’s Manual addendum 4. High altitude jet: 263-62463-08 - for EH64, 20.5hp 3. Install the high altitude jet into the carburetor using a flat head screw driver. EH65, 22.0hp 263-62640-08 - for EH72 25.0hp - 45 - EH64, EH65 Performer OHV220 Robin Subaru - V-Twin Service Update - Welder Applications Note: FUEL PUMP A diaphragm type fuel pump is located either in front of the engine below the aircleaner or on the oil filter side of the engine. The pump utilizes pressure changes in the crankcase to actuate a diaphragm to pump the fuel. Oil capacity: 53 oz. (1.55 Liters) Use SAE #20, #30 or 10W-30 class SE or higher automobile engine oil. Be certain it is not overfilled. 2. Check hose and hose connections for leaks. If cracked or damaged, replace. 3. Replace fuel pump using the new high lift pump. Part number: 280-62201-00 Blue dot PROBLEM Hard starting. Can not get fuel to carburetor. This condition could be cause by the following: • Overfilling crankcase with oil Fig 1 - Revised New Design - Blue Paint Mark The new High Lift fuel pump can be identified by the Blue dot, as shown below in figure 1. • High Ambient Temperatures • High Altitude Note: CORRECTIVE ACTION 1. Check the oil level. Overfilling will block the fuel pump breather port. EH64, EH65 Performer OHV220 - 46 - If operating above 5,000 feet, you may need to change the main jets when replacing the fuel pump. See High altitude section. Robin Subaru - V-Twin Service Update - Welder Applications SPARK PLUG PROBLEM Hard starting when the engine is cold. The engine will run on one cylinder but is hard starting. CORRECTIVE ACTION Check for a fouled spark plug. The correct spark plug is NGK BPR4EY, Pro V. This plug has a split center electrode, called the V-Groove. ENGINE OPERATION WHILE DISCONECTED FROM WELDER CONTROL BOARD For Miller Electric and Hobart Welder Applications Only Should you need to “hot-wire” the engine for testing purposes on the Miller Welder, the following wires need to be connected after the plug has been disconnected from the welder portion. This procedure may be required to test the engine separate from the welder start -stop circuit. This forces the spark to the outer edge of the ground electrode, placing it closer to the air/fuel mixture. Note: plug is located behind side panel on the center This allows the spark to more quickly ignite the mix- support bracket. ture, providing more complete combustion. Run Condition-Connect Red and Blue Wire The gap is set at 0.025 inches or .6 to .7mm. (places power to the bypass relay and ungrounds the magneto and puts power to the fuel solenoid). The EH65, 20.0hp, does not use the bypass relay. However, wiring connection will be the same. Crank Condition-Connect Yellow and Red Wire (cranks engine) After engine starts, disconnect the Yellow and Red crank wire circuit. Note: See the wiring diagram in the “Shutdown Relay” section. Part Number: X65-01407-30 - 47 - EH64, EH65 Performer OHV220 Service Hobart Champion & Miller Bobcat 225 & 250 Welders - 48 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders Removal & Installation Procedures of the Onan by Robin (OHV) V-Twin Engine on the Miller Bobcat 225 & 250 Series Welders, as well as the Hobart Champion 10,000 Should it become necessary to remove and install the Onan by Robin Engine in the Miller Bobcat 225 & 250 series welder, as well as the Hobart Champion 10000, the steps on the following pages should be followed. Note: This information is intended for a service professional. Follow all safety and operating procedures shown in the owners and service manuals. Onan by Robin 22hp (side view) Onan by Robin 22hp (back view) - 49 - Onan by Robin 20.5 hp (side view) Service Hobart Champion & Miller Bobcat 225 & 250 Welders 1. Remove the engine access doors and set aside. Note: These doors are lifted “up and out” from the engine frame. Note: Unless noted otherwise, the removal and installation procedures are similar for all models . 2. Remove the 8 bolts on the rear engine panel using a 3/8” wrench or socket. 3. Lift the ‘engine back panel’ away from the engine & frame and set aside. 4. Disconnect the negative battery lead first using a 1/2” wrench. Note: Always disconnect the spark plug wire before working on any part of the welder. This will prevent accidental starting of the unit. - 50 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 5. After disconnecting the battery positive terminal with the 1/2” wrench, remove the battery hold down bracket using a 7/16” wrench. Then remove the battery from the unit and set aside. 6. Remove the gas cap, exhaust pipe, and the 8 bolts that hold down the units top cover. Lift the cover off and set aside. 7. Remove the 2 bolts from each side panel. Lift the side panels out and set aside. Note: After removing the bolts, be careful to lift the side panels ‘up’ and ‘out’ of the welder frame, being careful not to let the panel drop. 8. Remove the choke cable from the engine control bracket after loosening the hold down clamp with a Phillips screwdriver. Note: Make sure to reinstall the bolt and top clamp bracket back into the control lever housing for later reinstallation. - 51 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 9. Remove the fuel line from the fuel pump. Note: If the fuel level is higher than the gas line coming out of the fuel tank, expect fuel to spill out of the fuel line when it is removed from the fuel pump. Be prepared to siphon or pump fuel out of the tank until the level of fuel drops below the level of the 90 degree fitting coming from the tank before removing the fuel line. Also, A small amount of fuel will spill from the fuel pump until it runs dry. 10. Mark and remove the two wires that go to the large white resistor located above the stator housing. 11. Mark and disconnect the wires that go to the brush block assembly. Note: Just remove the two white wires at this time. The brush block assembly will be removed in a later step. 12. Mark and disconnect the 4 auxiliary power (generator output leads) that go to terminal strip 1T. These leads are white in color. Bobcat 250---Leads-81A,90A,80A, & 82A Bobcat 225---Leads-81A,90A,80A, & 82A Champ 10K--Leads-51, 60, 52, & 53 Note: See Steps 19-a and 19-b for removal of generator output leads on the Hobart Champion 10000 - 52 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 13. A number of cable ties are used to keep the wires from interfering with the rotating components on the welder. Take note of proper location and placement. Note: To achieve original factory locations of wire ties, it might help by marking locations of wire ties with some type of marker pen. This will help in identifying original locations during reassembly. 14. Cut only the necessary cable ties from the wiring harness. 15. Pull apart the 4-plug connector near the terminal strip. 16. Pull apart the 4 pin plug connector on the center upright housing. - 53 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 17. Remove the female plug connector from the center upright housing. 18. Remove the two bolts that hold the component panel from the center upright support, and set aside. Note: Components and wiring do not need to be removed from the panel. 19. Hobart Champion Only Note: The Hobart Champion 10000 generator auxiliary power output leads must be removed from the terminal strip shown in the picture. 20. Remove the 4 bolts that hold the center upright in position. Before lifting straight up and away from the unit, push the sides of the upright center mount together to push the pins out of holes in the base (these are locking pins). Note: When reinstalling the center upright back into the frame, make sure the bottom edge of upright fits into the split tabs of the fuel tank cover. - 54 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 21-a. Bobcat 250 Only Remove the three thick black stator output leads that are attached to the Course-Range Switch, as well as the fourth thick black stator lead that goes through the red donut to the rectifier. Make sure to mark the wires for proper reassembly. Lead 10--through the donut to the rectifier Lead 11---to # 4 on Course Range Switch Lead 12---to # 2 on Course Range Switch Lead 13---to # 11 on Course Range Switch Note: Make sure to torque to 9 ft lbs when reinstalling the welder leads. 21-b. Bobcat 225 Only Remove the two thick black stator output leads that are attached to the Course-Range Switch as well as the third thick black stator lead that goes through the red donut to the rectifier. Make sure to mark the wires for proper reassembly. Lead 10--through the donut to the rectifier Lead 11---to # 6 on Course Range Switch Lead 12---to # 11 on Course Range Switch Note: Make sure to torque to 9 ft lbs when reinstalling the welder leads. 21 c. Hobart Champion 10000 Only Remove the two thick black welder output leads (#’s70 & 71) that go to the middle plate of the rectifier assembly. Note: Lead 70 goes directly to the rectifier from the donut. Note: Make sure to torque to 9 ft lbs when reinstalling the welder leads. 22. Remove the 4 bolts that hold the front control panel to the frame. Pull the front panel back about 1 or 2 inches. Note: This will improve access to the leads that go to the rectifier assembly. - 55 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 23. Using two wrenches, remove the nut that holds the thick black stator wire bolted to the rectifier on the stabilizer reactor assembly. See Step 21-c for Hobart Champion instructions. Note: Leave the bolt & nut in hole for later re-installation. 24. Pull the last thick black stator wire through the red donut. 25. Remove the ground strap from the frame near the engine. 26. After removing the air cleaner cover, loosen, but do not remove the 4 upper blower housing bolts that holds the blower housing to the engine block. Next, remove the 2 bottom blower housing bolts from the engine block. After lifting the carburetor vacuum hose from the blower housing, pull the blower housing away from the engine and set aside. Note: For the Champion 10000, the fuel pump and fuel pump bracket must be removed before the blower housing is removed. Take care not to loose the two spacers located behind the bracket bolts. - 56 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 27. Should you have access to the Miller special tools that mounts on the flywheel, install them at this point in the disassembly. Rotor Removal Tool-Miller Part # 147551 Rotor Removal Tool Spacer-Miller Part # 177126 Note: If you do not have the Miller special tools go to step 29. 28. At this point it should be noted that the welder rotor must first be “broken loose” from the engine crankshaft before any further disassembly. This procedure entails holding the flywheel in a locked position. It must be noted that quite a bit of force will be needed to break the rotor loose. The rotor must be turned in a counterclockwise position. The threads on the engine crankshaft are threaded similar to a standard bolt. 29. If you do not have the special Miller tools, then the procedure shown will also work for holding the flywheel. First remove the 4 bolts & fan shroud that are attached to the flywheel and set aside. Next, drill a hole in the angle iron for the bolt to attach the angle iron to the flywheel. Now, bolt the angle iron, or suitable mounting device to the flywheel as shown. 30. Place some type of protection between the angle iron and the welder frame to prevent scratching. - 57 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 31. A large pipe wrench must be placed over the rotor extension to loosen the rotor. The rotor extension has flats on each side of the shaft for the pipe wrench to grip. 32. To break the rotor loose from the threaded crankshaft, a fairly large pipe wrench must be placed over the rotor extension. Make sure all wires are out of the way before turning the wrench. 33. It may become necessary to place a “cheater” pipe over the end of the wrench to “encourage” the loosening process. The pipe wrench will be turned in a counterclockwise position. When the rotor has begun to turn freely, turn a few more revolutions on the wrench to make sure it is loose. 34. Be prepared to use force (turning in a counter clockwise position) to loosen the rotor from the crankshaft. - 58 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 35. Loosen and remove the ground bolt from the frame of the unit using a 3/8” socket. 36. Loosen and remove the (3 bolts for the Hobart Champion), (5 bolts for the Bobcat) that hold the stabilizer reactor assembly to the base of the frame using a 1/2” socket and a long extension. After these bolts are removed, slide the entire assembly forward a couple of inches. Note: This allows access to the stator mounting bolt shown in the next couple of steps. Note: The stabilizer reactor bolts must be properly torqued to 175 inch lbs for reassembly. 37. The stator mounting bolt is shown for identification. Access to this bolt and nut is shown in Step 38. 38. Reaching under the cross member of the welder frame, loosen and remove the nut that is attached to the bolt (shown in previous picture) which protrudes from the stator housing through the welder cross member frame. - 59 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 39. Loosen and remove the two engine mounting bolts and nuts. Note: The engine and stator are mounted to the frame with rubber mounts (two mounts on the engine side, one on the generator housing side). Should these mounts ever need to be removed, reinstallation is accomplished using water (or soapy water) applied to the rubber surface before reinstallation into the welder frame. 40. Placing a strap between the engine and the generator assembly, lift upwards and away from the frame making sure no wires are left attached. 41. Place entire unit on a bench or cart for further disassembly. 42. Loosen and remove the brush block assembly from the rear of the stator housing. Note: Be careful when pulling the brush block assembly away from the slip rings as to not damage the brushes. - 60 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 43. Loosen and remove the four stator housing bolts using a 9/16” socket. Note: Make sure to torque these bolts to 35 ft lbs when reassembly is done. 44. Using two pry bars, gently pry the stator assembly away from the engine adapter housing. Note: Be careful, stator assembly is heavy (close to 100 lbs). Note: Care must be taken not to damage the windings when removing. After removal, set aside being careful not damage stator windings when setting down. 45. The rotor can now be turned off in a counter clockwise position. Lift slightly while turning to relieve tension on crankshaft. Note: The rotor is also heavy. (50-60lbs) 46. After removal of the rotor from the crankshaft, carefully set the rotor aside making sure not to damage the rotor windings. - 61 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 47. Loosen and remove the 4 adapter housing bolts using a 5/8” socket before removing the housing from engine. Note: Make sure to torque 40 ft lbs when reassembly is done. 48. Should it become necessary for testing purposes to run the engine after removal from welder, follow the procedures on “hot-wiring” in the Robin/Onan service tips. 49. Before reassembly of rotor to crankshaft, make sure to apply anti-sieze compound to the threaded crankshaft. Note: Also apply a very small amount to the crankshaft shoulder. 50. Reassemble generator parts in reverse order making sure to torque bolts as noted. Torque adapter housing bolts to 40 ft. lbs. - 62 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders 51. Turn the rotor on the crankshaft in a clockwise position. Note: Spin the rotor assembly hand tight on the crankshaft. 52. Carefully place the stator over the rotor, making sure not to scratch or rub against each other. Note: Torque to 35 ft lbs after placing stator bolts into housing. 53. Always use cable ties when reassembling wiring harness wires. This will prevent wires from moving or rubbing against sharp objects. Note: Try to place as close to the original positions that came from the factory. 54. After adding oil and gas to the welder, make sure all connections are secure. Start and run the welder until operating temperature is achieved, checking for engine leaks or other possible reassembly issues. - 63 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders Exploded View of Parts Remove brush assembly before removing front generator housing - 64 - Service Hobart Champion & Miller Bobcat 225 & 250 Welders Generator Parts Identification Apply anti-seize compound (Loctite 76732) to all contacting surfaces between rotor and engine. Torques: A 40ft lb (54 N-m) B 35ft lb (47 N-m) C 25 in lb (3 N-m) D 18 ft lb (24 N-m) 1.O-Ring 2.Front Generator Housing 3.Stator Windings 4.Rear Generator Housing 5.Generator Fan 6.Rotor 7.Slip Rings 8.Bearing 9.Brush Holder Assembly - 65 - Service Miller Trailblazer 301G Welders - 66 - Service Miller Trailblazer 301G Welders Removal & Installation Procedure for the Onan Performer Engine (OHV) on Miller Trailblazer 301 G Welders Onan by Robin 22hp (side view) Onan by Robin 20.5 hp (side view) - 67 - Service Miller Trailblazer 301G Welders 1. Remove the 14 bolts from the top cover. Lift the cover off and set aside. Note: The gas cap will need to be removed before lifting the cover off. 2. Next, remove the 4 bolts that hold the two side covers in place. Lift the side covers straight up and set aside. 3. Remove the bolts from the welder engine cover. Lift the cover off and set aside. 4. Loosen and remove the 4 battery bracket bolts from the welder frame. - 68 - Service Miller Trailblazer 301G Welders 5. Loosen the battery connections. Always remove negative side first. 6. Slide the battery tray forward, and out of the frame, grabbing the battery case strap and setting aside. 7. Remove the male engine wiring harness plug from the female portion, that is mounted in the middle stator support bracket. 8. Remove the clamp and fuel hose from the gas tank male connection. Be aware that fuel will spill from fuel line. Note: Should the gas level be higher than the 90° elbow shown in the picture, (filled into neck of tank) gas will spill from the fitting until the level is even with the elbow. Be prepared to siphon or drain this extra fuel out of the tank before working on unit. - 69 - Service Miller Trailblazer 301G Welders 9. Loosen and remove the choke cable bracket from its seat. Un-hook and remove the cable from carburetor linkage. Replace hold down clamp and tighten loosely for later reassembly. 10. Loosen and remove the two bolts that hold the fuel pump support from the front engine cover. Be sure to save the two spacers over the bolts that are behind the angle iron bracket for later reassembly. 11. Loosen but do not remove the four engine shroud bolts that hold the cover to the engine. Loosen and remove the two bottom shroud bolts from the engine block. 12. Remove the engine shroud cover and set aside. - 70 - Service Miller Trailblazer 301G Welders 13. Loosen and remove the four flywheel fan blade bolts and remove from flywheel. 14. At this point it should be noted that the welder rotor must first be broken loose from the engine crankshaft before any further disassembly. This procedure entails holding the flywheel in a locked position. It must be noted that quite a bit of force will be needed to break the rotor loose. Shown in the picture is one way to hold the flywheel in position. It is simply a piece of angle iron with a hole drilled to mount a bolt to the flywheel. Special tools are also available for purchase for holding the flywheel from Miller Electric. 15. To break the rotor loose from the crankshaft, a fairly large pipe wrench must be placed over the rotor extension. The area around the rotor extension is surrounded by quite a few wires. Some of these wires should be moved aside for greater leverage. This is accomplished by removing wires from the circuit board and setting aside. 16. After removing these wires from the circuit board, pull them through the circuit board access hole and set aside. - 71 - Service Miller Trailblazer 301G Welders 17. Shown to the right is a picture of the type of socket used on these brush holder screws. The brush holders might also use a Phillips type of screw head. 18. Loosen and remove the two special torx type head screws from the brush holder. (Note: there are two brush holders on each model) 19. After removal of the screws, pull the brush holders out of the way. 20. Shown the right is the special D-type rotor shaft that extends beyond the end of the end bracket hous ing. This is where the large pipe wrench will be attached to loosen the rotor from the engine. - 72 - Service Miller Trailblazer 301G Welders 21. Carefully place the wrench between the wires on extended rotor shaft and turn counter clockwise to loosen the rotor from the crankshaft. When the rotor has begun to turn freely, turn a few more pulls on the wrench to make sure it is loose. 22. It may become necessary to place a cheater pipe on the end of the large pipe wrench to encourage the loosening process. 23. Loosen and remove the four stator though bolts that hold the end bracket housing to the stator shell. 24. Loosen and remove the two bolts that hold the engine assembly to the engine frame bracket. - 73 - Service Miller Trailblazer 301G Welders 25. Loosen and remove the four engine cross member bolts. Note: Make sure the engine is supported by some type of overhead lift. 26. Support engine with chain hoist and a 2 x4 before beginning to move forward. 27. While supporting the engine with the 2 x 4, slowly pull engine and rotor forward making sure not to let rotor hit on the stator windings. It may be necessary to support rotor with board as it comes out. 28. This is what the engine & rotor unit will look like when removed. Be careful not to let rotor hit against other objects. - 74 - Service Miller Trailblazer 301G Welders 29. With the engine supported, turn rotor counter clock wise until un-threaded from crankshaft. 30. Remove the adapter plate and splash shield and set aside. The engine is now ready for service. 31. Re-installation requires that the splash shield be placed and the back of the engine. 32. Before turning the rotor on the crankshaft make sure to wipe anti-sieze compound of the crankshaft threads. - 75 - Service Miller Trailblazer 301G Welders 33. When re-assembling the rotor to the engine crankshaft, turn the rotor clockwise hand tight until snug. The rotor will tighten itself completely the first time the engine is started. 34. Re-installation of the rotor and engine into the stator shell must be done with care. Keep supporting the rotor so as not to hit or scratch the stator windings. If needed, use the four stator bolt nuts to pull the engine and rotor into final position when the adapter bolts protrude through the stator end bracket. Re-install the remaining components, place gas and oil into the welder and test for proper operation. - 76 - PRINTED IN THE USA
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