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.
7-5. Adjusting Engine Speed (Honda-Powered Units)
1400 ± 150 rpm
3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)
2
1
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 (60 Hz) position.
Turn screw and move lever until engine runs at weld/power speed.
Idle Speed Adjustment
3 Pilot Screw
4 Throttle Stop Screw
Move lever to idle position. Turn pilot screw until engine runs at highest idle speed. Turn stop screw until
engine runs at rated idle speed
(normally about 2-1/4 turns out.)
Y Stop engine. Close fuel
valve.
Tools Needed:
3
4
1/4, 3/8 in
802 097-A
TM-499 Page 21
SECTION 8 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
fields.
2 Revolving Field (Rotor)
Turns at 3700 rpm maximum (60
Hz) for weld and power. The speed
and excitation current of the field
coils determine voltages in stator
windings.
3 Stator Windings
Supply power to exciter, generator
power, and weld circuits.
4 Integrated Rectifier SR1
Changes ac output of stator
windings to dc to supply excitation
current to the exciter revolving field.
5 Control Board PC1
Adjusts weld output by changing
revolving field current after
comparing feedback to amperage
setting of R1.
Uses current feedback signal for
foldback circuit to prevent stator
failure from short-circuit conditions.
Use voltage feedback signal to
maintain open-circuit and generator power voltages regardless of
Current Control R1 setting.
Monitors engine speed and stops
weld and power output when speed
drops below 2700 rpm.
6 Current Control R1
Changes output of stator weld
windings by adjusting field current
level in revolving field.
7 Generator Power Circuit
Breakers
Protect ac receptacles from overload.
8 Generator Power AC
Receptacles
Provide connection points and
power for auxiliary equipment.
5
Engine
Engine Speed Feedback Signal
AC Supply
Control
Board
PC1
8
Generator
Power AC
Receptacles
7
Generator Power
Circuit
Breakers
213
Revolving
Field
(Rotor)
Excitation DC Supply
6
Generator Power
Stator Windings
Exciter
4
Integrated
Rectifier
SR1
Weld
TM-499 Page 22
Current
Control R1
9
Main Rectifier
SR2
Voltage Feedback Signal
Voltage Feedback Signal
10
Suppressor
VR1/R2
9 Main Rectifier SR2
Changes ac weld current to dc.
10 Suppressor VR1/R2
Protects SR2 from overload.
11 Stabilizer L1
Smooths weld output current.
12 Shunt
Provides weld current feedback to
control board PC1.
13 HF Filter Board PC2
Protects unit from high frequency.
14 Positive (+) And Negative (−)
Weld Output Terminals
Provide weld output.
Current Feedback Signal
12
Shunt
13
HF Filter
Board
14 14
Positive (+)
Weld Output
Terminal
Electrode Work
11
PC2
Stabilizer
L1
Negative (−)
Weld Output
Terminal
AC Or DC Control Circuits
Weld Current Circuit
Mechanical Coupling
Magnetic Coupling
TM-499 Page 23
SECTION 9 − EXPLANATION OF ELECTRICAL PARTS
9-1. Safety Precautions − Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.
D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
BATTERY A source of DC voltage. Typically used in
Engine Driven equipment.
+
elect_parts 7/04
BRUSHES/SLIP
RINGS
Components that allow electrical connections
between stationary and rotating contacts.
CAPACITOR A device that stores electrical energy. Large
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk”
capacitors can be used for HF protection.
CHASSIS The green ground wire of a primary cord is
connected to the machine frame (chassis) for
safety. Also, you may find many “HF bypass”
capacitors connected to chassis to reduce
High Frequency interference. Expect to see
this symbol used numerous times in circuit
diagrams. The picture shown here is from an
Engine Drive where several wires including
the battery are connected to the chassis.
CIRCUIT BREAKER A protection device that breaks a circuit when
current levels exceed its rating. Unlike a fuse
that needs to be replaced when blown, a
circuit breaker can be reset.
SLIP
RINGS
BRUSHES
POLARIZED NON-POL.
+
C1
CB1
C1
CIRCUIT COMMON When many wires are connected together,
rather than showing all the “lines” and “dots”,
this symbol may appear on the circuit. Look
for other Circuit Common symbols on a
circuit diagram. For instance, say 10 symbols
are found on a circuit, this means all ten
points are electrically tied together.
TM-499 Page 24
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
CLAMP A spring-loaded connection device. A good
example would be the “work clamp” used to
connect the weld cable from a power source
to the workpiece that will be welded.
CONTACTOR A heavy duty relay. Usually used to make
and break the welding arc or primary power.
CURRENT
TRANSFORMER
A transformer that produces an AC voltage
used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current.
DASHED LINE A dashed line between parts means there is
a mechanical connection between these
parts. When a dashed line boxes in parts,
this means the parts make up an option or
are combined into one part. In all cases,
dashed lines do not conduct electricity. The
picture shown is a combination fan motor and
transformer in one part.
W
NRM OPEN
POINTS
CT1
OR
CT1
FM
COIL
W
DIODE A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
FAN MOTOR This device provides cooling of the internal
parts of a welding power source.
FUSE A protection device, usually an enclosed
piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
GAS OR WATER
SOLENOID
(VALVE)
These are electromechanical devices used to
start or stop the flow of shielding gas or
water.
HALL DEVICE Produces a small DC voltage proportional to
the current it is sensing (usually welding
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
D1
FM
F1
GS1
OR
WS1
HD1
TM-499 Page 25
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
IGBT A device that is used as an “electronic
switch”. When a signal is applied to the gate
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically
used in “Inverter” designed welding machines
to control the welding output.
INTEGRATED
BRIDGE
An arrangement of four diodes used to
change AC to DC.
RECTIFIER
INTEGRATED
CIRCUIT
IC’s often called “chips” provide a complete
circuit function with inputs and outputs. A
good example would be the “Pulse Width
Modulation” chip used in many wire feeder
designs.
JUMPER LINK Usually, the jumper link is a piece of brass
that connects two terminals together. Dashed
lines indicate possible locations for other
jumper links.
LIGHT EMITTING
DIODE
This device usually referred to by its initials
LED is used to tell you when a particular
circuit is activated. This function is very
helpful for troubleshooting.
AC
C1
G1 (B1)
E1
+
+
−
AC
AC
AC
_
U1
TE1
D1
MAGNETIC
AMPLIFIER
This device usually referred to as a
“Mag-Amp” is made up of coil windings and
an iron core similar to a transformer. It
controls a large welding current by varying a
small “control current”.
METER A measuring device. A “voltmeter” is a good
example.
MOSFET A device that is used as an “electronic
switch”. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
to control a relay, the speed of a motor, or
even the output of a welding machine.
MA1
V = voltmeter
V
G
AS
A = ammeter
HM = hour
meter
D
S
TM-499 Page 26
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
CO
MOTOR A device that converts electrical energy into
mechanical energy. Typically used to feed
wire in a MIG welding system, or pump
coolant in a recirculating liquid-cooling
system.
OPERATIONAL
AMPLIFIER
Usually referred to as an “Op-Amp”, this IC
chip is very versatile and widely used on PC
boards. A typical use might be as a
“comparator”, comparing the command
signal to the feedback signal allowing the
welding output to be kept constant.
OPTICAL
COUPLER
A device that uses “light” to get electrical
separation (isolation). This eliminates noise
that might be in one circuit from affecting
another circuit.
PILOT LIGHT A light located on the front panel which
indicates if the machine is on or off.
POTENTIOMETER
OR
RHEOSTAT
Both devices have a moveable brush that
makes contact along a resistor, allowing you
to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
M1 = DC
+
A1
_
OC1
R1
= AC
1
M1
PL
CW = CLOCKWISE
CCW =COUNTER-
CLOCKWISE
PLUG A connection device that hangs loose with
wires coming out the back of it. Please note
that the plug terminals can be either male or
female.
RECEPTACLE A connection device that is mounted or fixed.
Just like a plug, the terminals can be either
male or female.
RELAY−−COIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is an electromechanical device whose
contacts change state (the normally open
points close and the normally closed points
open) when proper voltage is applied to the
coil. These contact points in turn may control
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show
the contact points in the power off state.
RESISTOR A device which resists the flow of electric
current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
RIBBON CABLE A connection device where the wires are laid
out flat. Usually to connect circuits from one
PC board to another PC board.
MALE
FEMALE
PLG1
RC1
CR1 CR1
NRM OPEN
POINTS
FIXED
FIXED TAPPED
26-CONDUCTOR
RC54 RC44
PLG =
LOOSE
MALE
FEMALE
RC =
MOUNTED
IL
CR1
NRM CLOSED
POINTS
R1
R1
CABLE
TM-499 Page 27
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
SCR A Silicon Controlled Rectifier (SCR) is an
electrical device with three connections,
anode, cathode, and gate. It will allow current
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to
control the output to a load such as a welding
arc.
SHUNT A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
SNUBBER A device used to absorb voltage spikes,
sometimes found connected across the
points of a relay.
SPARK GAP The arrangement of two electrodes between
which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding.
STABILIZER/
REACTOR
When placed in a DC circuit, the inductor or
stabilizer as it is usually called, will oppose
any change in existing current. It is therefore
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
K
A
SHUNT
SN1
G
Z1
L1
G
SWITCH
A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
A multi-pole switch will use dashed lines to
connect poles.
MOMENTARY
SWITCH
SPST = S
SPDT = S
DPST = D
DPDT = D
A switch that “springs back” to its original
position.
ingle Pole Single Throw
ingle Pole Double Throw
ouble Pole Single Throw
ouble Pole Double Throw
LIMIT SWITCH A switch mounted in the path of a moving
object and actuated by its passage.
PUSH BUTTON
SWITCH
A switch in which a button must be
depressed each time the contacts are to be
opened or closed.
ROTARY SWITCH A switch in which its shaft must be rotated to
actuate the contacts.
SPDTSPST
S1
NRM OPEN NRM
S1
NRM
OPEN
PB1 PB1
CLOSED
S1
NRM
CLOSED
DPDTDPST
TM-499 Page 28
S1 S1
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
PRESSURE
SWITCH
TEMPERATURE
SWITCH
WATER FLOW
SWITCH
TERMINAL
ASSEMBLY
A change in the pressure of a gas or liquid
will actuate this switch.
Typically used to protect engines, this switch
is actuated by heat.
A switch that is actuated by the flow of a
liquid. Typically used to protect
“water-cooled” torches.
A connection point for primary power and the
jumper links that are used to match the input
voltage to the machine. Usually, the terminal
assembly is marked with the letters “TE”, but
the electrical symbol looks identical to a
standard terminal strip.
OPENS
ON
INCREASE
S1 S1
OPENS
ON
INCREASE
S1
OPENS
ON
INCREASE
S1
TE1
INCREASE
INCREASE
S1
INCREASE
S1
CLOSES
ON
CLOSES
ON
CLOSES
ON
TERMINAL STRIP An insulated connection point for wires. They
are used for the ease of making multiple
connections and can be a convenient point
for making electrical checks when
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
THERMISTOR A thermally sensitive resistor. There are two
types of thermistor, PTC (Positive
Temperature Coefficient) and NTC (Negative
Temperature Coefficient). A PTC thermistor’s
resistance will increase as the temperature
goes up, where as an NTC thermistor’s
resistance will decrease as the temperature
goes up. Primarily used for “Fan on Demand”
and “Thermal Shutdown” circuits.
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is a switch that closes its normally open
contacts (or opens its normally closed
contacts) when a preset temperature is
reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when
needed and shutting off the output of a
welding power source if it is overheating.
TRANSISTOR Most commonly used as an electronic switch.
There are two basic types, PNP and NPN.
This refers to their internal design, which
determines current flow direction.
42 42 104 105 74
1T
AB CDE
104 105
RT1
OR
TH1
NRM OPEN
Q1 Q1
B
NPN PNP
NRM CLOSED
C
E
TE1
TP1TP1
C
B
E
TM-499 Page 29
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
TRANSFORMER A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
TRIAC An electronic AC switch. It is turned on by a
gate signal similar to an SCR.
TWISTED WIRE Wires are twisted to prevent “electrical noise”
from interfering with the circuit. A good
example is the red and white gate leads
going to an SCR. Typically, these wires are
twisted together to help prevent the SCR
from misfiring.
VARISTOR A protection device whose resistance is
dependent on the voltage applied to it. In
normal operation it has a high resistance;
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
T1
T1
T1
IRON
CORE
FERRITE
CORE
AIR
CORE
Q1
RED
WHT
VR1
WIRES WITH
CONNECTION
When lines (wires) cross on a circuit diagram
and there is a “black dot”, this means that the
two wires are electrically connected together.
The method of connection (bolted, friction
lugs, etc.) is not indicated with this symbol.
However, a “white dot” indicates that the
method of connection is a terminal strip. Of
course, no dot means no connection.
TM-499 Page 30
SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
A. Welding
Trouble Remedy
No weld output. Check weld connections.
Disconnect equipment from receptacles when starting unit.
Check resistance and connections of resistor R3; R3 is 20 ohms ±5%. Replace R3 if necessary.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is
too low.
Check slip rings, and install new brushes if necessary (see Section 10-7).
Check resistance and connections of Current Control R1; R1 is 0 to 1000 ohms ±10%. Replace R1 if
necessary.
Check control board PC1 and connections, and replace if necessary (see Section 10-5). PC1 LED lights
when board is energized.
Check engine lamp coil and connections, and replace coil if necessary. Lamp coil supplies power to control board PC1. PC1 LED lights when board is energized (see Section 10-5).
. See Section 10-2 for test points and
values and Section 13 and following
for parts location.
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Check integrated rectifier SR1, and replace if necessary.
Check diodes in main rectifier SR2, and replace if open.
Disconnect stator weld leads from main rectifier SR2, and check continuity between stator weld leads.
Replace stator if necessary.
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Disconnect stator exciter leads (black) from integrated rectifier SR1, and check continuity between
exciter leads. Replace stator if necessary.
Low weld output. Check Current Control R1 setting.
Check throttle lever setting.
Check weld cable size and length.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Service air cleaner according to engine manual.
Check slip rings, and install new brushes if necessary (see Section 10-7).
Check control board PC1 and connections, and replace if necessary (see Section 10-5). PC1 LED lights
when board is energized.
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Check integrated rectifier SR1, and replace if necessary.
Check diodes in main rectifier SR2, and replace if open.
Disconnect stator weld leads from main rectifier SR2, and check continuity between stator weld leads.
Replace stator if necessary.
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Disconnect stator exciter leads (black) from integrated rectifier SR1, and check continuity between
exciter leads. Replace stator if necessary.
TM-499 Page 31
Trouble Remedy
High weld output. Check Current Control R1 setting.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Check resistance and connections of suppressor VR1/R2. R2 is 1000 ohms ±5%. Replace VR1/R2 if
necessary.
Check slip rings, and install new brushes if necessary (see Section 10-7).
Check control board PC1 and connections, and replace if necessary (see Section 10-5). Replace PC1
if shorted across receptacle RC4 pins 4 and 6. PC1 LED lights when board is energized.
Check capacitor C1 replace if open. If C1 is open, also replace circuit board PC1.
Check diodes in main rectifier SR2, and replace if shorted.
Erratic weld output. Check Current Control R1 setting.
Tighten and clean connections to electrode and workpiece.
Tighten and clean connections inside and outside welding generator.
Use dry, properly-stored electrodes for SMAW.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Check throttle/governor linkage for smooth, non-binding operation.
Check slip rings, and install new brushes if necessary.
Check control board PC1 and connections, and replace if necessary. PC1 LED lights when board is energized.
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Check integrated rectifier SR1, and replace if necessary.
Check diodes in main rectifier SR2, and replace if open.
Check stabilizer L1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace L1 if necessary.
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
B. Generator Power
Trouble Remedy
No output at ac receptacles. Reset circuit breakers (see Section 6-1).
Check connections to control board PC1.
Check receptacle wiring and connections.
Check resistance and connections of resistor R3; R3 is 20 ohms ±5%. Replace R3 if necessary.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is
too low.
Check slip rings, and install new brushes if necessary (see Section 10-7).
Check control board PC1 and connections, and replace if necessary (see Section 10-5). PC1 LED lights
when board is energized.
TM-499 Page 32
Check engine lamp coil and connections, and replace coil if necessary. Lamp coil supplies power to control board PC1. PC1 LED lights when board is energized.
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Check integrated rectifier SR1, and replace if necessary.
Check diodes in main rectifier SR2, and replace if open.
Disconnect stator generator power leads from connection block 1T, and check continuity between generator power leads 1 and 3, and leads 2 and 4. Replace stator if necessary.
Trouble Remedy
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Disconnect stator exciter leads (black) from integrated rectifier SR1, and check continuity between
exciter leads. Replace stator if necessary.
High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Move throttle lever to Run (use 50 Hz position for 50 Hz equipment).
Check control board PC1 and connections, and replace if necessary (see Section 10-5). Replace PC1
if shorted across receptacle RC4 pins 4 and 6. PC1 LED lights when board is energized.
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Low power output at ac receptacles. Move throttle lever to Run (use 60 Hz position for 60 Hz equipment).
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Check capacitor C1 for a short or open, and replace if necessary. If C1 is open, also replace circuit board
PC1.
Check integrated rectifier SR1, and replace if necessary.
Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if
necessary.
Erratic power output at ac receptacles. Check fuel level.
Check receptacle wiring and connections.
Check throttle/governor linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Check slip rings, and install new brushes if necessary (see Section 10-7).
Check control board PC1 and connections, and replace if necessary. PC1 LED lights when board is energized.
C. Engine
Trouble Remedy
Engine will not crank (electric-start
models only).
Engine will not start. Check fuel level (see Section 4-4 or 4-5).
Reset ignition circuit breaker.
Check battery voltage.
Check battery connections and tighten if necessary.
Check engine ignition circuit, and replace components if necessary.
Open fuel valve (see Section 4-4 or 4-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check battery voltage (electric-start models only).
Check battery connections and tighten if necessary (electric-start models only).
Check oil level (see Section 4-4 or 4-5). Engine stops if oil level is too low. Refill crankcase with proper
viscosity oil for operating temperature.
Check low oil level shutdown switch, and replace if necessary.
TM-499 Page 33
Trouble Remedy
Engine stopped during normal
operation.
Check fuel level (see Section 4-4 or 4-5).
Open fuel valve (see Section 4-4 or 4-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check oil level (see Section 4-4 or 4-5). Engine stops if oil level is too low.
Check low oil level shutdown switch, and replace if necessary.
Check unit operating angle. Low oil level shutdown switch may stop engine if unit is tilted.
Battery discharges between uses (electric-start models only).
Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
TM-499 Page 34
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
TM-499 Page 35
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
V1,
R3
R8
V2,
R4
R1
V4
V3, R5
I1
V10
R6
V5
See Section 10-4 for
waveforms A,B,C,D
See Section 8 for
PC2 information
V6, A, B
C, D
V11
R2
V9,
R7
TM-499 Page 36
V9,
R7
See also
Section 10-5
for PC1 data
V7
V8
197 857-E
TM-499 Page 37
10-3. Test Points And Values (Use With Section 10-2)
Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70
°F (21°C); cold
machine (no warm-up); no load
c) Weld/power rpm unless specified
d) Reference − single arrow: reference
to circuit common (lead 11); double
arrow: reference to points indicated
e) Wiring Diagram − see Section 12
V1 122 volts ac ±5% (60 Hz)
110 volts ac ±5% (50 Hz)
V2 122 volts ac ±5% (60 Hz)
110 volts ac ±5% (50 Hz)
V3 76 volts ac (60 Hz)
69 volts ac (50 Hz)
V4 50 volts dc (60 Hz)
70 volts dc (50 Hz)
V5 At 25 volt, 100 ampere weld load:
Less than 1 volt dc (60 and 50 Hz)
V6 68 volts dc (60 Hz)
62 volts dc (50 Hz)
V7 0 − 10 volts dc (60 or 50 Hz)
V8 15 volts dc (60 or 50 Hz)
V9 23.5 volts ac (60 Hz)
20.5 volts ac (50 Hz)
V10 200 volts dc (60 Hz)
176 volts dc (50 Hz)
V11 18.2 volts ac (60 Hz) − Kohler Only
15.5 volts ac (50 Hz) − Kohler Only
Amperage Readings
a) Tolerance − ±5% unless specified
b) Condition − 70
°F (21°C); cold
machine (no warm-up); no load
I1 1.8 amps dc (60 Hz)
2.3 amps dc (50 Hz)
Resistance Values
a) Tolerance − ±10% unless specified
b) Condition − 70
°F (21°C); cold
machine (no warm-up)
c) Wiring Diagram − see Section 12
d) Stop engine before checking
resistance
R1 27 ohms
R2 20 ohms (Kohler Only)
R3 thru R8 Less than 1 ohm
Test Equipment Needed:
TM-499 Page 38
10-4. Waveforms For Section 10-2
Waveforms shown are for 60 Hertz models;
waveforms for 50 Hertz models are similar.
gnd
A. DC/CC Open-Circuit Voltage, No Load, 60 Hz
5 ms 50 V
5 ms 20 V
gnd
B. 25 Volts DC, 185 Amperes (Resistive Load), 60 Hz
Test Equipment Needed:
TM-499 Page 39
10-5. Control Board PC1 Testing Information
Be sure plugs are secure before
testing. See Section 10-6 for
specific values during testing.
1 Receptacle RC5
2
3
1
2 Receptacle RC4
3 LED1
LED1 lights when board is
energized.
Test Equipment Needed:
TM-499 Page 40
802 524 / 198 221-A
10-6. Control Board PC1 Test Point Values
PC1 Voltage Readings
Receptacle Pin Value
RC4 1 18 volts ac input with respect to pin 2
2 18 volts ac input with respect to pin 1
3 +50 volts dc output with respect to pin 4
4 −50 volts dc output with respect to pin 3
5 +200 volts dc input with respect to pin 6
6 Circuit common
7 Circuit common (shield) for shunt input
8 Shunt negative (circuit common)
9 Shunt positive (less than 1 volt dc input with respect to pin 8 with 100 ampere, 25 volt weld load
RC5 1 0 volts dc
2 +15 volts dc input
a) Tolerance −
±10% unless
specified
b) Condition − no load; throttle
lever in 60 Hz position
c) Reference − to circuit common
(RC4-7) unless noted
3 Circuit common
4 +10 volts dc output with respect to pin 6
5 0 to +10 volts dc input from min. to max. of Current Control R1 with respect to pin 6
6 Circuit common
7 Weld feedback input; same as negative (−) weld output terminal voltage
8 0 volts dc
9 0 volts dc when engine speed is greater than 2800 rpm
TM-499 Page 41
10-7. Replacing Brushes And Cleaning Slip Rings
3
1/4 in (6 mm)
Or Less − Replace
4
7/16 in − 1/2 in
(11 − 12 mm) New
Y Stop engine.
1 Generator End Panel
2 Brush Assembly
3 Brush Holder
4 Brushes
Remove end panel. Remove brush
assembly. Pull brushes from
holders.
Replace brushes if damaged, or if
brush is at or near minimum length.
5 Slip Rings
Visually inspect slip rings. Under
normal use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Y Stop engine. Close fuel
valve.
Install brushes, brush holders, and
brush arm.
Reinstall cover.
2
1
Tools Needed:
TM-499 Page 42
ST-802 524 / ST-801 842
10-8. Checking Unit Output After Servicing
2
1
Start engine.
Move throttle control lever to 60 Hz
position.
1 Weld Output Terminals
Check open-circuit voltage across
weld output terminals. There
should be 68 volts dc present (see
Section 10-2).
2 AC Receptacles RC1, RC2,
And RC3
Move throttle lever to correct
position (50 or 60 Hz) for generator
power. Check voltage at each
receptacle. With no load applied,
voltage should be 10% above
receptacle rating on nameplate.
EXAMPLE: Correct no load voltage
for a 120 volt receptacle should be
132 volts ac.
If generator power or weld output
voltage is incorrect, adjust engine
speed (see Section 7-4 or 7-5).
Y Stop engine. Close fuel
valve.
Allow engine to cool, and complete
pre-operational checks in table.
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-4 or 4-5).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Test Equipment Needed:
Pre-Operational Checks
ST-802 524
TM-499 Page 43
SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
Use Section 10-2 to determine if
trouble is in stator, rotor, engine or
combination of these components.
Remove cover. Mark and disconnect stator leads.
Disassemble in sequence shown.
Y Use hoist and lifting strap to
carefully remove engine/
generator assembly.
Go to Section 11-2.
TM-499 Page 44
Tools Needed:
802 524
11-2. Removing Rotor And Reassembling Generator
Removing Rotor
1
2
1 in
(25.4 mm)
5/16 in
(8 mm)
Cut screwdriver
slot in end of rod.
Reassembling Generator
7-1/2 in
(191 mm)
24 threads
per inch
Y Do not damage rotor or sta-
tor windings during this procedure.
To remove rotor:
1 Rotor Removal Tool
(Customer Supplied)
2 Screw, 7/16-14 x 1-1/4
(Customer Supplied)
Remove rotor thru-bolt.
Make rotor removal tool from
stress-proof steel rod according to
specifications. Slide threaded end
of tool through rotor. Tighten tool in
engine shaft. Turn screw into rotor
while lightly tapping rotor laminations. (turning screw into rotor
forces rotor off engine shaft.)
Reassembly
3 Brushholder Assembly
4 Generator End Panel
5 Bearing Carrier
6 Rotor Assembly
7 Stator Assembly
8 Generator Fan
9 Generator Guard
10 Engine Adapter
11 Engine
Reinstall engine and generator
parts using torque values in table.
Reconnect all leads. Use cable ties
to secure leads in wiring harness
and away from moving or hot parts.
Reinstall cover.
11
3
10
9
8
7
6
A
4
5
B
Tools Needed:
Torques:
A 95 in lb (10.7 N.m)
B 205 in lb (23.1 N.m)
802 524 / 802 509
TM-499 Page 45
SECTION 12 − ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number
Welding Generator LA124002 and following (Kohler)
Generator Power Panels LA124002 and following (Kohler)
Circuit Board PC1 LA124002 and following (Kohler)
Circuit Board PC2 LA124002 and following (Kohler)
NOTE
LA347885 and following (Honda)
LA347885 and following (Honda)
LA033425 and following (Honda)
KH467216 and following (Honda)
The circuits for Honda-powered units were implemented prior to the effective date
of this manual.
Circuit
Diagram
197 857-E 197 858-C
201 026-A
198 222
SA-148 611-A
Wiring
Diagram
Figure 12-1. Circuit Diagram For HF Board PC2 Eff. w/ Serial No. LA124002 And Following (Kohler)
Or KH467216 And Following (Honda)
TM-499 Page 46
SA-148 611-A
Figure 12-2. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA347885 And Following (Honda) (1 Of 2)
TM-499 Page 47
197 857-E
197 857-E
Figure 12-3. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA347885 And Following (Honda) (2 Of 2)
TM-499 Page 48
197 858-C
Figure 12-4. Wiring Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA347885 And Following (Honda)
TM-499 Page 49
Apply small amount of conductive electric compound (Part No. 603 978) to terminals where
factory-applied compound had been present.
Figure 12-5. Wiring Diagram For Generator Power Panels Eff. w/ Serial No. LA124002 And
TM-499 Page 50
201 026-A
Following (Kohler) Or LA347885 And Following (Honda) (1 Of 2)
Apply small amount of conductive electric compound (Part No. 603 978) to terminals where
factory-applied compound had been present.
Figure 12-6. Wiring Diagram For Generator Power Panels Eff. w/ Serial No. LA124002 And
Following (Kohler) Or LA347885 And Following (Honda) (2 Of 2)
TM-499 Page 51
201 026-A
SC-198 222
Figure 12-7. Circuit Diagram For Control Board PC1 Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA033425 And Following (Honda)
TM-499 Page 52
TM-499C August 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Eff w/LA124002 Thru LB111747
(Kohler Only)
For OM-499 (197 850) Revisions * Thru B
SECTION 13 − PARTS LIST FOR LA124002 THRU LB111747
(KOHLER ONLY)
12
13
14
15
16
17
18
19
20
21
. Hardware i s common and
not available unless listed.
26
25
24
22
27
11
28
10
9
8
2
1
6
5
4
3
47
48
46
45
444243
41
40
39
38
37
23
7
31
32
33
34
35
36
49
29
30
802 509
TM-499 Page 54
Figure 13-1. Main Assembly
Eff w/LA124002 Thru LB111747 (Kohler Only)
Item
No.
1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 096 LABEL, precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 SR1 035 704 RECTIFIER, integ bridge 40 A 800 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC2 148 608 BOARD, PC filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 495 095 LABEL, moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 495 094 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 194 509 FAN, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 495 211 GENERATOR, w/stator assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 495 113 LEAD, bonding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 194 504 FRAME, mtg assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 R1 035 897 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 Figure 13-2 PANEL, gen power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 R3 197 795 RESISTOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 188 039 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Figure 13-1. Main Assembly
495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-499 Page 55
Eff w/LA124002 Thru LB111747 (Kohler Only)
. Hardware i s common and not available unless listed.
23 5
1
Generator Power Panel 196 914 (CSA)
12
4
9
6
7
Generator Power Panel 495 315
11 13
12
14
8
10
14
Generator Power Panel 495 253
(South Africa)
Generator Power Panel 495 289
(Australia)
Figure 13-2. Generator Power Panels
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 13-2. Generator Power Panels (Figure 13-1, Item 39)
Generator Power Panel 196 914 (CSA)
1 CB1, CB2 495 182 Circuit Breaker, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 RC1 407 749 Receptacle, Twistlock 240V U.S. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 RC2, RC3 408 898 Receptacle, Duplex 115V 20A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 196 909 Label,120/240V Gen Power Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 196 911 Panel,120/240V Gen Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 CB3, CB4 495 246 Circuit Breaker, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 188 039 Cover, Receptacle W/Gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 315
8 495 314 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 CB1, CB2 495 245 Circuit Breaker, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CB3, CB4 495 246 Circuit Breaker, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 253 (South Africa)
11 495 252 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 CB1, CB2 495 245 Circuit Breaker, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 289 (Australia)
13 495 254 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 CB1 - CB4 495 245 Circuit Breaker, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196 921
Quantity
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-499 Page 56
TM-499C August 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Eff w/LB111748 Thru LC061260 (Kohler)
Eff w/LB086216 Thru LC061260 (Honda)
For OM-499 (197 850) Revision C
SECTION 14 − PARTS LIST FOR LB111748 THRU LC061260 (KOHLER)
AND LB086216 THRU LC061260 (HONDA)
12
13
14
15
16
17
18
19
20
21
. Hardware i s common and
not available unless listed.
26
25
24
22
27
11
28
10
9
49
8
2
1
6
5
4
3
47
48
46
45
444243
41
40
39
38
37
23
7
31
32
33
34
35
36
49
29
30
802 509-A
TM-499 Page 58
Figure 14-1. Main Assembly
Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 096 LABEL, precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 SR1 035 704 RECTIFIER, integ bridge 40 A 800 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 129 525 TERMINAL, output Dinse 50/70 series (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC2 148 608 BOARD, PC filter (CSA only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 204 140 LABEL, moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 204 138 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 055 ENGINE, Honda 13HP (recoil start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 053 ENGINE, Honda 13HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 194 509 FAN, generator (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 493 868 FAN, generator (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 495 211 GENERATOR, w/stator assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 495 113 LEAD, bonding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 194 504 FRAME, mtg assembly (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 495 132 FRAME, mtg assembly (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 R1 035 897 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 Figure 14-2 PANEL, gen power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Figure 14-1. Main Assembly
129 527 PLUG, weld cable (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 952 FILTER, air Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 954 FILTER, air pre Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 955 CAP, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 956 TANK, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 957 STRAINER, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 958 MUFFLER, exhaust engine Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 959 GASKET, muffler Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 960 SPARK PLUG, Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
TM-499 Page 59
Quantity
Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 R3 197 795 RESISTOR ASSEMBLY (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 201 223 LABEL, warning electric shock power still present 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 188 039 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Mkgs.
Part
No.
Description
Figure 14-1. Main Assembly (Continued)
Quantity
TM-499 Page 60
Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
11
15
23
1
Generator Power Panel 196 914 (CSA)
12
Generator Power Panel 495 253
(South Africa)
16
19
4
5
6
7
. Hardware i s common and not available unless listed.
8
9
10
Generator Power Panel 495 315 (USA)
14
13
14
12
Generator Power Panel 495 289
(Australia)
21
17
18
22
23
20
27
24
30
28
31
Generator Power Panel 495 219
(USA)
Generator Power Panel 495 288
(S. America)
Generator Power Panel 495 298
(USA)
Figure 14-2. Generator Power Panels
29
32
33
25
35
26
Generator Power Panel 495 290
(Europe)
Generator Power Panel 495 283
(S.E. Asia)
Generator Power Panel 495 278
(Canada−CSA)
TM-499 Page 61
34
36
196 921
Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
Generator Power Panel 196 914 (CSA)
1 CB1, CB2 495 182 Circuit Breaker, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 RC1 407 749 Receptacle, Twistlock 240V U.S. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 RC2, RC3 408 898 Receptacle, Duplex 115V 20A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 196 909 Label,120/240V Gen Power Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 196 911 Panel,120/240V Gen Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 CB3, CB4 495 246 Circuit Breaker, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 188 039 Cover, Receptacle W/Gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 315 (USA)
8 495 314 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 CB1, CB2 495 245 Circuit Breaker, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CB3, CB4 495 246 Circuit Breaker, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 253 (South Africa)
11 495 252 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 CB1, CB2 495 245 Circuit Breaker, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 289 (Australia)
13 495 254 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 CB1 - CB4 495 245 Circuit Breaker, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 219 (USA)
15 495 220 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 495 217 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 290 (Europe)
21 495 282 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 288 (S. America)
23 495 287 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 CB1-4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 283 (S.E. Asia)
25 495 282 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 298 (USA)
27 495 220 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 RC1 007 467 RECEPTACLE, tw lk grd 2P3W 30A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 278 (Canada−CSA)
32 495 277 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 RC2 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-499 Page 62
Dia.
Mkgs.
Part
No.
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
605 797 PLUG, tw lk 3P3W 20A 125V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
Description
Figure 14-2. Generator Power Panels (Figure 14-1, Item 39)
Quantity
TM-499C August 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Eff w/LC061261 Thru LC552236
(Kohler & Honda)
For OM-499 (197 850) Revisions D Thru F
SECTION 15 − PARTS LIST FOR LC061261 THRU LC552236
(KOHLER & HONDA)
12
13
14
15
16
17
18
19
20
21
. Hardware i s common and
not available unless listed.
26
25
24
22
27
11
28
10
9
49
8
2
1
6
5
4
3
47
48
46
45
444243
41
40
39
38
37
23
7
31
32
33
34
35
36
50
29
30
802 509-A
TM-499 Page 64
Figure 15-1. Main Assembly
Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 096 LABEL, precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 SR1 035 704 RECTIFIER, integ bridge 40 A 800 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 129 525 TERMINAL, output Dinse 50/70 series (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC2 148 608 BOARD, PC filter (CSA only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 204 140 LABEL, moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 204 138 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 055 ENGINE, Honda 13HP (recoil start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 053 ENGINE, Honda 13HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 194 509 FAN, generator (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 493 868 FAN, generator (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 495 211 GENERATOR, w/stator assembly (Prior to LC232853) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 204 469 GENERATOR, w/stator assembly (Eff w/LC232853) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 495 113 LEAD, bonding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 194 504 FRAME, mtg assembly (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 495 132 FRAME, mtg assembly (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 R1 035 897 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 Figure 15-2 PANEL, gen power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Figure 15-1. Main Assembly
129 527 PLUG, weld cable (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 952 FILTER, air Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 954 FILTER, air pre Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 955 CAP, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 956 TANK, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 957 STRAINER, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 958 MUFFLER, exhaust engine Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 959 GASKET, muffler Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 960 SPARK PLUG, Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
TM-499 Page 65
Quantity
Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 R3 197 795 RESISTOR ASSEMBLY (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 201 223 LABEL, warning electric shock power still present 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 188 039 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Mkgs.
Part
No.
Description
Figure 15-1. Main Assembly (Continued)
Quantity
TM-499 Page 66
Eff w/LC061261 Thru LC552236 (Kohler & Honda)
4536
1
2
Generator Power Panel 495 218 (USA)
12
13
13
. Hardware i s common and not available unless listed.
7
8
9 11
Generator Power Panel 495 315 (USA)
14
15
Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia)
16
17
20
18
19
22
23
10
15
21
Generator Power Panel 495 219 (USA)
24
25
Generator Power Panel 495 288 (S. America)
28
29
31
30
Generator Power Panel 495 290 (Europe)
26
27
Generator Power Panel 495 283 (S.E. Asia)
33
34
36
35
37
32
Generator Power Panel 495 298 (USA)
Figure 15-2. Generator Power Panels
Generator Power Panel 495 278 (Canada−CSA)
TM-499 Page 67
Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
Generator Power Panel 495 218 (USA)
1 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 216 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 007 467 RECEPTACLE, twistlock grd 2P3W 30A 125 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 408 898 RECEPTACLE, duplex 115 V 20 A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 315 (USA)
7 495 314 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 404 089 RECEPTACLE, Duplex 230 V S. American 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 408 898 RECEPTACLE, Duplex 115 V 20 A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 253 (South Africa)
12 495 252 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 289 (Australia)
14 495 254 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 CB1 - CB4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 219 (USA)
16 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 217 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 290 (Europe)
22 495 282 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 288 (S. America)
24 495 287 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 CB1-4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 283 (S.E. Asia)
26 495 282 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 298 (USA)
28 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 RC1 007 467 RECEPTACLE, tw lk grd 2P3W 30A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 278 (Canada−CSA)
33 495 277 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 CB1 203 095 CIRCUIT BREAKER, 25A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 RC2 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-499 Page 68
Dia.
Mkgs.
Part
No.
Figure 15-2. Generator Power Panels (Figure 15-1, Item 39)
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
605 797 PLUG, tw lk 3P3W 20A 125V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
202 631 COVER, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 630 BRACKET, mtg circuit breaker cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-499C August 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Eff w/LC552237 And Following
(Kohler & Honda)
For OM-499 (197 850) Revisions G And H
SECTION 16 − PARTS LIST FOR LC552237 AND FOLLOWING
12
13
14
15
16
17
18
19
20
21
. Hardware i s common and
not available unless listed.
26
25
24
22
27
11
28
10
9
49
8
2
1
6
5
4
3
47
48
46
45
444243
41
40
39
38
37
23
7
31
32
33
34
35
36
50
29
30
802 509-A
TM-499 Page 70
Figure 16-1. Main Assembly
Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 096 LABEL, precautionary (Prior to LE130162) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 SR1 035 704 RECTIFIER, integ bridge 40 A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 129 525 TERMINAL, output Dinse 50/70 series (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC2 148 608 BOARD, PC filter (CSA only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 204 140 LABEL, moving parts (Prior to LE130162) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 211 297 LABEL, general precautionary (Eff w/LE130162) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 204 138 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 055 ENGINE, Honda 13HP (recoil start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 +495 053 ENGINE, Honda 13HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 194 509 FAN, generator (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 493 868 FAN, generator (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 204 469 GENERATOR, w/stator assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 495 113 LEAD, bonding (Prior to LE100004) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 194 504 FRAME, mtg assembly (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 495 132 FRAME, mtg assembly (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 R1 207 083 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 207 077 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Figure 16-1. Main Assembly
129 527 PLUG, weld cable (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 952 FILTER, air Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 954 FILTER, air pre Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 955 CAP, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 956 TANK, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 957 STRAINER, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 958 MUFFLER, exhaust engine Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 959 GASKET, muffler Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*203 960 SPARK PLUG, Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-499 Page 71
Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 Figure 16-2 PANEL, gen power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 R3 197 795 RESISTOR ASSEMBLY (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 201 223 LABEL, warning electric shock power still present (CSA) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 188 039 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Mkgs.
Part
No.
Description
Figure 16-1. Main Assembly (Continued)
Quantity
TM-499 Page 72
Eff w/LC552237 And Following (Kohler & Honda)
4536
1
2
Generator Power Panel 495 218 (USA)
12
13
13
. Hardware i s common and not available unless listed.
7
8
9 11
Generator Power Panel 495 315 (USA)
14
15
Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia)
16
17
20
18
19
22
23
10
15
21
Generator Power Panel 495 219 (USA)
24
25
Generator Power Panel 495 288 (S. America)
28
29
31
30
Generator Power Panel 495 290 (Europe)
26
27
Generator Power Panel 495 283 (S.E. Asia)
33
34
36
35
37
32
Generator Power Panel 495 298 (USA)
Figure 16-2. Generator Power Panels
Generator Power Panel 495 278 (Canada−CSA)
TM-499 Page 73
Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
Generator Power Panel 495 218 (USA)
1 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 495 216 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 007 467 RECEPTACLE, twistlock grd 2P3W 30A 125 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 408 898 RECEPTACLE, duplex 115 V 20 A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 315 (USA)
7 495 314 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 404 089 RECEPTACLE, Duplex 230 V S. American 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 408 898 RECEPTACLE, Duplex 115 V 20 A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 253 (South Africa)
12 495 252 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 289 (Australia)
14 495 254 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 CB1 - CB4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 219 (USA)
16 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 495 217 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 290 (Europe)
22 495 282 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 288 (S. America)
24 495 287 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 CB1-4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 283 (S.E. Asia)
26 495 282 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 298 (USA)
28 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 RC1 007 467 RECEPTACLE, tw lk grd 2P3W 30A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Power Panel 495 278 (Canada−CSA)
33 495 277 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 CB1 203 095 CIRCUIT BREAKER, 25A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 RC2 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Mkgs.
Part
No.
Figure 16-2. Generator Power Panels (Figure 16-1, Item 39)
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
605 797 PLUG, tw lk 3P3W 20A 125V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
202 631 COVER, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 630 BRACKET, mtg circuit breaker cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .
073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-499 Page 74
Notes
PRINTED IN USA 2004 Miller Electric Mfg. Co.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
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