Miller Electric TM-499C User Manual
TM-499C August 2004
Eff. w/Serial Number LA124002 (Kohler)
Eff. w/Serial Number LB086216 (Honda)
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
R
Blue Star 6000
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption (Kohler-Powered Units) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption (Honda-Powered Units) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Generator Power Curves 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Volt-Ampere Curves 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Grounding Generator To Truck Or Trailer Frame 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Grounding Generator When Supplying Building Systems 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Engine Prestart Checks (Kohler-Powered Units) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Engine Prestart Checks (Honda-Powered Units) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting The Battery (Electric-Start Models Only) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATING THE WELDING GENERATOR 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls (Kohler-Powered Units) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Controls (Honda-Powered Units) (See Section 5-3) 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) 14 . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING AUXILIARY EQUIPMENT 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Generator Power Panel 495 218 (USA) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional Generator Power Panels 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Generator Power Panel Ratings 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) 18 . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Maintenance Label 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Routine Maintenance 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Overload Protection (Honda-Powered Units) 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Adjusting Engine Speed (Kohler-Powered Units) 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed (Honda-Powered Units) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − THEORY OF OPERATION 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − EXPLANATION OF ELECTRICAL PARTS 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − TROUBLESHOOTING 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) 36 . . . . . . . . . . . . . .
10-3. Test Points And Values (Use With Section 10-2) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Waveforms For Section 10-2 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Control Board PC1 Testing Information 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Control Board PC1 Test Point Values 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Replacing Brushes And Cleaning Slip Rings 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Checking Unit Output After Servicing 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
SECTION 11 − DISASSEMBLY AND REASSEMBLY 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Removing Rotor And Reassembling Generator 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ELECTRICAL DIAGRAMS 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST FOR LA124002 THRU LB111747 (KOHLER ONLY) 54 . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − PARTS LIST FOR LB111748 THRU LC061260 (KOHLER) AND
SECTION 15 − PARTS LIST FOR LC061261 THRU LC552236
SECTION 16 − PARTS LIST FOR LC552237 AND FOLLOWING 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LB086216 THRU LC061260 (HONDA) 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(KOHLER & HONDA) 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-499H, safety_rtm 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should test, maintain, and repair this
unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un-
less the procedure specifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
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 actions
to avoid the hazards.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ENGINE EXHAUST GASES can kill.
D Do not breathe exhaust fumes.
D Use in open, well-ventilated areas, or vent ex-
haust outside and away from any building air intakes.
FUEL can cause fire or explosion.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
D Keep away from moving parts such as
fans, belts, and rotors.
D Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from mov-
ing parts.
D Before working on generator, remove spark plugs or injec-
tors to keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on gener-
ator components.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connect-
ing battery cables.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and −) on batteries.
D Disconnect negative (−) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
TM-499 Page 1
STEAM AND HOT COOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
FALLING UNIT can cause injury.
D Use equipment of adequate capacity to lift and
support unit and components.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Securely attach components to lifting equip-
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
TILTING OR TIPPING can cause injury.
D Do not put any body part under unit while lifting.
D Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
D Be careful when working on stator and rotor assemblies.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OVERUSE can cause OVERHEATING.
HOT PARTS can cause severe burns.
D Allow cooling period before servicing.
D Wear protective gloves and clothing when
working on a hot engine.
D Do not touch hot engine parts bare-handed.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
1-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-499 Page 2
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
2-1. Symbol Definitions
SECTION 2 − DEFINITIONS
h
NOTE
Engine Choke
Engine Oil Fuel Battery (Engine) Engine
Positive Negative
Hours
Read Operator’s
Manual A
Alternating Current
Seconds Time
Amperes
(AC)
V
Output
Protective Earth
(Ground)
s
Circuit Breaker Temperature
SECTION 3 − SPECIFICATIONS
This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.
Volts
3-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
40 − 180 A
(60 Hz)
40 − 160 A
(50 Hz)
Rated
Welding
Output
180 A, 25 V,
30% Duty
Cycle
130 A, 25 V,
60% Duty
Cycle
100 A, 25 V,
100% Duty
Cycle
Maximum
Open Circuit
Voltage
80
(60 Hz)
70
(50 Hz)
Generator Power
Rating
Single-Phase,
6 kVA/kW (Peak)
5.5 kVA/kW
(Continuous)
50/25 A,
110/220 V AC, 50 Hz
120/240 V AC, 60 Hz
Fuel Capacity Engine
Kohler CS12STG
Air-Cooled,
One-Cylinder,
Kohler:
1.8 gal (6.9 L) Tank
Honda:
1.7 gal (6.4 L) Tank
Four-Cycle,
12 HP (360 CC),
Gasoline Engine
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
OR
TM-499 Page 3
3-2. Dimensions, Weights, And Operating Angles
B
Y Do not move or operate unit where it
15°
°
G
15°
Holes
Dimensions
Height 20-3/4 in (527 mm)
Width 22-3/4 in (577 mm)
Depth 31-1/4 in (793 mm)
A 31-1/4 in (793 mm)
B 10-1/2 in (268 mm)
C 13-45/64 in (348 mm)
D 22-3/4 in (577 mm)
E 1-3/4 in (44 mm)
F 19-1/2 in (495 mm)
G 13/32 in (10 mm) Dia.
Weight
Kohler: 265 lb (120 kg)
Honda Electric-Start Model:
278 lb (126 kg)
Honda Recoil-Start Model:
253 lb (114 kg)
A
C
E
D
F
Engine End
3-3. Fuel Consumption (Kohler-Powered Units)
G
4
Holes
802 096
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
could tip.
15
°
°
°
15°
802 524-A
. Fuel consumption at low idle
(2000 rpm): 0.2 U.S. gal/hr.
60 HZ−WELD
60 HZ−AUX
50 HZ−AUX
50 HZ−WELD
HIGH IDLE
198 575
TM-499 Page 4
3-4. Fuel Consumption (Honda-Powered Units)
3-5. Duty Cycle
802 122
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
100% Duty Cycle at 100 Amperes CC/DC
802 093
TM-499 Page 5
3-6. Generator Power Curves
A. 60 Hz Model
250
225
200
175
150
125
LOAD VOLTS
100
75
50
25
The generator power curves show
the ac power available in amperes
at the receptacles.
0
0 5 10 15 20 25 30 35
B. 50 Hz Model
250
225
200
175
150
125
LOAD VOLTS
100
75
50
LOAD AMPS
25
0
TM-499 Page 6
0 5 10 15 20 25 30 35
LOAD AMPS
198 570
3-7. Volt-Ampere Curves
A. 60 Hz Model
80
70
60
50
40
LOAD VOLTS
30
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
MAX
MID
20
10
0
0 25 50 75 100 125 150 175 200 225 250
MIN
LOAD AMPS
B. 50 Hz Model
80
70
60
50
40
LOAD VOLTS
30
MID
20
MIN
MAX
10
0
0 25 50 75 100 125 150 175 200 225 250
LOAD AMPS
198 570
TM-499 Page 7
SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Movement Airflow Clearance
(460 mm)
18 in
(460 mm)
Y Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
18 in
18 in
(460 mm)
18 in
(460 mm)
Location
OR
4-2. Grounding Generator To Truck Or Trailer Frame
1
GND/PE
OR
3
18 in
(460 mm)
install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-0854
Y Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding
Terminal
4
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
Y If unit does not have GFCI re-
ceptacles, use GFCIprotected extension cord.
TM-499 Page 8
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
2
2
install1 10/00* − Ref. 151 556 / S-0854
4-3. Grounding Generator When Supplying Building Systems
GND/PE
Use ground device as
stated in electrical codes.
1 2
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
Y Ground generator to sys-
tem earth ground if supplying power to a premises
(home, shop, farm) wiring
system.
2
3
4-4. Engine Prestart Checks (Kohler-Powered Units)
1/2 in
(13 mm)
Gasoline
1
Closed
Closed
Open
Full
Full
800 576-B
. Follow run-in procedure in engine
manual.
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Engine stops if oil level gets too low.
. This unit has a low oil level shut-
down switch. However, some conditions may cause engine damage
before the engine shuts down.
Check oil level often and do not use
the oil level shutdown system to
monitor oil level.
1 Fuel Valve
Open valve by turning lever to vertical
position.
. Close fuel valve before moving unit
or carburetor may flood and make
starting difficult.
Fuel
Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in.
(13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day.
Oil
After fueling, check oil with unit on level
surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).
. T o improve cold weather starting:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
802 511-A
TM-499 Page 9
4-5. Engine Prestart Checks (Honda-Powered Units)
1/2 in
(13 mm)
Gasoline
1
Open
Full
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Engine stops if oil level gets too low.
. Follow run-in procedure in en-
gine manual.
1 Fuel Valve
Open valve.
. Close fuel valve before moving
unit or carburetor may flood
and make starting difficult.
Fuel
Add fresh fuel before starting
engine the first time (see maintenance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Check fuel level on a cold engine
before use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
. To improve cold weather
starting:
Keep battery in good condition.
Store battery in warm area.
Full
4-6. Connecting The Battery (Electric-Start Models Only)
Y Connect negative (−)
cable last.
+
−
Use correct grade oil for cold
weather.
802 094-A
Y Turn Engine Switch to Off
(electric-start models only).
Tools Needed:
TM-499 Page 10
3/8, 1/2 in
802 524 / Ref. S-0756-D
4-7. Connecting To Weld Output Terminals
12
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
For Direct Current Electrode Positive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode negative (DCEN), reverse cable connections.
Tools Needed:
3/4 in
4-8. Selecting Weld Cable Sizes*
100 ft (30 m) or Less
Weld Output
Terminals
Y Stop engine before
connecting to weld output terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Welding
Amperes
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
10 − 60%
Duty
Cycle
196 914 / 495 178
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
60 − 100%
Duty
10 − 100% Duty Cycle
Cycle
400 ft
(120 m)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
TM-499 Page 11
SECTION 5 − OPERATING THE WELDING GENERATOR
5-1. Controls (Kohler-Powered Units)
6
2
3
50 Hz
60 Hz
1
4
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
1 Engine Switch
Use switch to open ignition circuit, and to stop
engine.
2 Throttle Control Lever
Use lever to select engine speed. Use 50 Hz
or 60 Hz position for 50 or 60 Hz generator
power. Use 60 Hz position for maximum weld
output.
3 Choke Control Lever
Use lever to change engine air/fuel mix. Move
lever to right if starting a cold engine. Move lever to left if starting a warm engine.
To Start (Electric): open fuel valve (see Section 4-4), move throttle lever to Idle, set choke,
and turn engine switch to Start position. Open
choke as engine warms. If engine does not
crank, use recoil starting procedure following
to start engine.
Y If engine does not start, let engine
come to a complete stop before attempting restart.
4 Starter Handle
To Start (Recoil): open fuel valve (see Section 4-4), move throttle lever to Idle, set choke,
and pull starter handle. Open choke as engine
warms.
To Stop: turn engine switch to Off.
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
5
7
802 511-A / 802 0511 / 495 178
5 Engine Hour Meter
6 Welding Range Label
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
7 Current Control
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to determine correct size electrode for material thickness. Select electrode type and set current
control to corresponding amperage range.
Adjust control to obtain desired weld
performance.
EXAMPLE:
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
TM-499 Page 12
5-2. Controls (Honda-Powered Units) (See Section 5-3)
3
6
60 Hz
4
Recoil-Start
1
2
50 Hz
Electric-Start
1
5
7
802 094-A / 802 095 / 495 187
TM-499 Page 13
5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2)
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
1 Engine Switch
On models with recoil-start, use switch to
open ignition circuit, and to stop engine.
On models with electric-start, use switch to
open ignition circuit, and to start and stop engine.
2 Throttle Control Lever
Use lever to select engine speed. Use 50 Hz
or 60 Hz position for generator power. Use 60
Hz position for maximum weld output.
3 Choke Control Lever
Use lever to change engine air/fuel mix. Move
lever to left if starting a cold engine. Move lever to right if starting a warm engine.
4 Starter Handle (Recoil-Start Models
Only)
Notes
To Start (Recoil): open fuel valve, turn engine
switch to On, move throttle lever to Idle, set
choke, and pull starter handle. Open choke as
engine warms.
To Start (Electric): open fuel valve, move
throttle lever to Idle, set choke, and turn engine switch to Start position. Open choke as
engine warms.
Y If engine does not start, let engine
come to a complete stop before attempting restart.
To Stop: turn engine switch to Off.
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
5 Engine Hour Meter
6 Welding Range Label
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
7 Current Control
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to determine correct size electrode for material thickness. Select electrode type and set current
control to corresponding amperage range on
nameplate. Adjust control within selected
range to obtain desired weld performance.
EXAMPLE:
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
TM-499 Page 14
SECTION 6 − OPERATING AUXILIARY EQUIPMENT
NOTE
The welding generator provides power while welding and with the Current control
in any position. However, under these conditions equipment connected to the
welding generator may be subject to larger than normal voltage fluctuations. It is
recommended that only lamps be powered under these conditions.
6-1. Generator Power Panel 495 218 (USA)
1234 5
Y If unit does not have GFCI recep-
tacles, use GFCI-protected extension cord.
Y Power is still present at the 240 volt
receptacle when only one circuit
breaker trips.
Unplug power cord before attempting to service accessories or tools.
. Generator power decreases as weld
current increa s e s .
Set Amperage control at max. for full
generator power.
. Place throttle lever in Run position (far
right) for generator power.
1 120 V AC Twistlock Receptacle RC1
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 3.5
kVA/kW.
2 120 V 20 A AC Duplex Receptacle
RC2
3 120 V 20 A AC Duplex Receptacle
RC3
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.
. Each receptacle of the duplex can pro-
vide 15A/1800W.
. Do not parallel the two 120V duplex
receptacles.
4 Circuit Breaker CB1
495 218
CB1 protects RC1 from overload. If CB1
opens, RC1 does not work.
5 Circuit Breakers CB2 And CB3
CB2 protects RC2 and CB3 protects RC3
from overload. If a circuit breaker opens,
the receptacle does not work.
. Press button to reset circuit breaker.
Combined output of all receptacles limited
to 6 kVA/kW rating of the generator. (See
Generator Power Guidelines in Owner’s
Manual.)
EXAMPLE: If 10 A is drawn from each 120
volt duplex receptacle, only 9 A is available
from the 120 V twistlock receptacle.
2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/
KW.
TM-499 Page 15
6-2. Optional Generator Power Panels
Generator Power Panel 495 315
Generator Power Panel 495 278
(Canada−CSA)
Generator Power Panel 495 219
(USA)
Generator Power Panel 495 253
(South Africa)
(USA)
Generator Power Panel 495 288
(South America)
Generator Power Panel 495 289
(Australia)
Y If unit does not have GFCI recep-
tacles, use GFCI-protected extension cord.
Y Power may still be present at a re-
ceptacle when a circuit breaker
trips.
Unplug power cord before attempting to service accessories or tools.
TM-499 Page 16
Generator Power Panel 495 290
(Europe)
. Generator power decreases as weld
current increases.
Set Amperage control at max. for full
generator power.
Generator Power Panel 495 283
(S.E. Asia)
Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277
. Place throttle lever in Run position (far
right) for generator power.
Circuit breakers protect the generator from
overload.
. Press button to reset circuit breaker.
6-3. Generator Power Panel Ratings
NOTE
Receptacle
240 V
Twist Lock
240 V
Duplex
240 V
Duplex
230 V
Single
230 V
Single
230 V
Single
230 V
Single
120 V
Twist Lock
120 V
Duplex
120 V
Duplex
120 V
Duplex
120 V
Duplex
Total
Power NOT
to exceed
Unless otherwise stated, the rating of duplex outlets is the combined load of all
receptacles.
Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)
Protected
By
CB1,2
CB1,2
CB3,4
CB1
CB2
CB1,2
CB3,4
CB1
CB1,3/
CB2,4
CB2
CB3
CB4
Panel
495 218
(USA)
60 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz
30A/
3500W
20A/
2400W
20A/
2400W
5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W
Panel
495 315
(USA)
15A/
3600W
See
Note 2
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
Panel
495 219
(USA)
25A/
5500W
See
Note 2
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
Panel
495 278
(Canada-
CSA)
25A/
5500W
See
Note 2
30A/
3600W
See
Note 1
Panel
495 253
(S. Africa)
15A/
3600W
15A/
3600W
Panel
495 288
(South
America)
15A/
3600W
15A/
3600W
Panel
495 289
(Australia)
15A/
3600W
15A/
3600W
Panel
495 290
(Europe)
15A/
3600W
15A/
3600W
Panel
495 283
(S.E. Asia)
15A/
3600W
15A/
3600W
Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.
2. Do not parallel the two 120V circuits.
3. Do not parallel the two duplex outlets.
Calculating total power provided by generator.
(See Generator Power Guidelines in Owner’s Manual.)
Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 5500W.
The rating plate on electrical apparatus will contain the watts
consumed or the rated input amps. Watts may be calculated by
multiplying the rated voltage by the rated input amps.
watts = volts x amps
For example, for the 495 218 Generator Power Panel,
120V, 3000W heater 3000W
120V, 10A chain saw 1200W
120V, 500W halogen lamp 500W
Total 4700W This loading is OK.
120V, 3000W heater 3000W
120V, 10A chain saw 1200W
120V, 5A router 600W
120V, 1000W halogen lamp 1000W
Total 5800W This loading is not OK.
It exceeds 5500W.
TM-499 Page 17
6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
2
Tools Needed:
6
120 V
1
3
120V
240 V
5
1 Plug Wired For 120/240 V,
3-Wire Load
When wired for 120 V loads, each duplex receptacle shares a load with
one half of the 240 V receptacle.
4
2 Neutral (Silver) Terminal
3 Load 1 (Brass) Terminal
4 Load 2 (Brass) Terminal
5 Ground (Green) Terminal
6 Cord Grip
Strip cord jacket back enough to separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip.
Tighten assembly screws onto shell.
Do not overtighten.
plug3-11/99 − 802 527
SECTION 7 − MAINTENANCE
NOTE
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
7-1. Maintenance Label
ENGINE MAINTENANCE
8 h
1.1 l (1.2 US qt,
1.94 lmp qt)
50 h
Unleaded
86 + Octane
6.5 l (1.7 US Gal,
11.4 lmp pt)
100 h
SG-SF/CC-CD
+40°C+104
+86+30
+20
+59
+10
+32
0
-10
-15
-20
-10
°F
10W-30
TM-499 Page 18
0.7 − 0.8 mm
(0.028 − 0.031 in)
200 h
Ref. S-175 679-A
7-2. Routine Maintenance
Recycle
engine
fluids.
Y Stop engine before maintaining.
. See Engine Manual and Maintenance Label. Ser-
vice more often if used in severe conditions.
* To be done by Factory Authorized Service Agent.
Check fluid
levels. See
Section 4-4
or 4-5
Service air cleaner
element. See engine
manual.
Change oil. See
engine manual and
maintenance label.
Clean Fuel
sediment cup.
8 h
Wipe up spills.
20 h
Check and clean
spark arrestor screen.
See engine manual.
50 h
Clean and
tighten weld
terminals.
100 h
Check
spark
plugs.
Clean and tighten battery
connections (Electric
-Start models only).
Clean fuel
tank and
strainer.
Repair or
replace cracked
cables.
Check valve
clearance.*
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
200 h
Replace
unreadable
labels.
300 h
500 h
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
1000 h
OR
TM-499 Page 19
7-3. Overload Protection (Honda-Powered Units)
1
7-4. Adjusting Engine Speed (Kohler-Powered Units)
2000 ± 150 rpm
3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)
Tools Needed:
1 Ignition Circuit Breaker
(Electric-Start Models Only)
The circuit breaker protects the engine battery charging circuit. A
short circuit or a battery connected
in reverse polarity will trip the circuit
breaker.
Press button to reset breaker.
. If breaker continues to open,
check starter solenoid (see en gine manual).
Ref. 802 094-A
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
Start engine and run until warm.
Weld/Power Speed
Adjustment
1 Throttle Control Lever
2 Adjustment Screw
Move lever to Run (far right) position. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To decrease speed, turn screw in (clockwise).
Idle Speed Adjustment
3 Adjustment Screw
Move lever to idle (far left) position.
To increase idle speed, turn screw
in (clockwise). To decrease idle
speed, turn screw out (counterclockwise).
Y Stop engine. Close fuel
valve.
TM-499 Page 20
Top View
Top View
3
2
1
802 511-A / Kohler Dwg.
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