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
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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
LB086216 THRU LC061260 (HONDA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
(KOHLER & HONDA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SECTION 16 − PARTS LIST FOR LC552237 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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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.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
. 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.
STATIC (ESD) can damage PC boards.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
Y
Y
Only qualified persons should test, maintain, and repair this
unit.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
ENGINE EXHAUST GASES can kill.
D
D
Do not touch live electrical parts.
D
D
Do not breathe exhaust fumes.
Stop engine before testing or repairing unit un-
less the procedure specifically requires an en-
ergized unit.
Use in open, well-ventilated areas, or vent ex-
haust outside and away from any building air in-
takes.
D
Insulateyourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground.
D
D
Do not leave live unit unattended.
When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D
Stop engine and let it cool off before checking or
adding fuel.
D
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
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.
BATTERY EXPLOSION can BLIND.
D
Have only qualified people remove
guards or covers for maintenance and
troubleshootingas necessary.
D
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D
Keep hands, hair, loose clothing, and tools away from mov-
ing parts.
D
Stop engine before disconnecting or connect-
ing battery cables.
D
D
D
Before working on generator, remove spark plugs or injec-
tors to keep engine from kicking back or starting.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Block flywheel so that it will not turn while working on gener-
ator components.
Disconnect negative (−) cable first and connect it last.
Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes.
BATTERY ACID can BURN SKIN and EYES.
D
Wear safety glasses with side shields or face
shield during servicing.
Be careful not to short metal tools, parts, or
wires together during testing and servicing.
D
D
D
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
D
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STEAM AND HOT COOLANT can burn.
TILTING OR TIPPING can cause injury.
D
D
Do not put any body part under unit while lifting.
D
D
D
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator.
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
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.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
H.F. RADIATION can cause interference.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with elec-
tronic equipment perform this installation.
MAGNETIC FIELDS can affect pacemakers.
D
Pacemaker wearers keep away from servicing
areas until consulting your doctor.
D
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
FALLING UNIT can cause injury.
D
D
D
Use equipment of adequate capacity to lift and
support unit and components.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Securely attach components to lifting equip-
ment.
If notified by the FCC about interference, stop using the equip-
ment at once.
D
D
Have the installation regularly checked and maintained.
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.
D
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERUSE can cause OVERHEATING.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
HOT PARTS can cause severe burns.
D
D
Allow cooling period before servicing.
Wear protective gloves and clothing when
working on a hot engine.
D
Do not block or filter airflow to unit.
D
Do not touch hot engine parts bare-handed.
READ INSTRUCTIONS.
D
D
D
Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Consult the Owner’s Manual for welding safety
precautions.
SHOCK HAZARD from testing.
D
D
D
Stop engine before making or changing meter
lead connections.
Use at least one meter lead that has a self-
retainingspring clip such as an alligator clip.
Use only genuine replacement parts.
D
Reinstall injectors and bleed air from fuel system according to
engine manual.
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.)
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
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
reproductiveharm. Wash hands after handling.
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.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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.
Welding current, as it flows through welding cables, will cause electro-
magnetic 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 power-
frequency 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.
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:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
TM-499 Page 2
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SECTION 2 − DEFINITIONS
2-1. Symbol Definitions
Read Operator’s
Amperes
Engine Choke
Volts
Manual
A
V
Engine Oil
Positive
Fuel
Battery (Engine)
Engine
Output
Alternating Current
(AC)
Negative
Seconds
Protective Earth
(Ground)
Hours
Time
s
h
Circuit Breaker
Temperature
SECTION 3 − SPECIFICATIONS
This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.
NOTE
3-1. Weld, Power, And Engine Specifications
Rated
Welding
Output
Maximum
Open Circuit
Voltage
Welding Weld Output
Generator Power
Rating
Fuel Capacity
Engine
Mode
Range
Kohler CS12STG
Air-Cooled,
One-Cylinder,
Four-Cycle,
12 HP (360 CC),
Gasoline Engine
OR
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
180 A, 25 V,
30% Duty
Cycle
Single-Phase,
6 kVA/kW (Peak)
5.5 kVA/kW
Kohler:
40 − 180 A
80
130 A, 25 V,
60% Duty
Cycle
1.8 gal (6.9 L) Tank
(60 Hz)
(60 Hz)
(Continuous)
CC/DC
40 − 160 A
(50 Hz)
70
(50 Hz)
50/25 A,
110/220 V AC, 50 Hz
120/240 V AC, 60 Hz
Honda:
1.7 gal (6.4 L) Tank
100 A, 25 V,
100% Duty
Cycle
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3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
20-3/4 in (527 mm)
22-3/4 in (577 mm)
31-1/4 in (793 mm)
31-1/4 in (793 mm)
10-1/2 in (268 mm)
13-45/64in (348 mm)
22-3/4 in (577 mm)
1-3/4 in (44 mm)
D
Width
Depth
Y
Y
Do not exceed tilt angles or engine could
be damaged or unit could tip.
B
C
A
B
C
D
E
F
Do not move or operate unit where it
could tip.
A
19-1/2 in (495 mm)
13/32 in (10 mm) Dia.
Weight
G
15°
15°
15°
G
4
15°
Kohler: 265 lb (120 kg)
Holes
Honda Electric-Start Model:
278 lb (126 kg)
Honda Recoil-Start Model:
253 lb (114 kg)
F
E
Engine End
802 524-A
802 096
3-3. Fuel Consumption (Kohler-Powered Units)
. 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
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3-4. Fuel Consumption (Honda-Powered Units)
802 122
3-5. Duty Cycle
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.
ContinuousWelding
100% Duty Cycle at 100 Amperes CC/DC
802 093
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3-6. Generator Power Curves
The generator power curves show
the ac power available in amperes
at the receptacles.
A. 60 Hz Model
250
225
200
175
150
125
100
75
50
25
0
0
5
10
15
20
LOAD AMPS
25
30
35
B. 50 Hz Model
250
225
200
175
150
125
100
75
50
25
0
0
5
10
15
20
LOAD AMPS
25
30
35
198 570
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3-7. Volt-Ampere Curves
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.
A. 60 Hz Model
80
70
60
50
40
30
MAX
MID
20
MIN
10
0
0
25
50
75
100
125
LOAD AMPS
150
175
200
225
250
B. 50 Hz Model
80
70
60
50
40
30
20
10
0
MAX
MID
MIN
0
25
50
75
100
125
150
175
200
225
250
LOAD AMPS
198 570
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SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Y
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
Movement
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Location
OR
install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-0854
4-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
3
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
3
1
4
Grounding Cable
4
GND/PE
Use #10 AWG or larger insulated
copper wire.
Y
If unit does not have GFCI re-
OR
ceptacles,
use
GFCI-
protected extension cord.
Electrically bond generator frame to
vehicle frame by metal-to-metal con-
tact.
2
2
install1 10/00* − Ref. 151 556 / S-0854
TM-499 Page 8
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4-3. Grounding Generator When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
GND/PE
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to sys-
tem earth ground if supply-
ing power to a premises
(home, shop, farm) wiring
system.
Use ground device as
stated in electrical codes.
2
3
800 576-B
4-4. Engine Prestart Checks (Kohler-Powered Units)
. 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.
1/2 in
(13 mm)
Full
Engine stops if oil level gets too low.
. This unit has a low oil level shut-
down switch. However, some con-
ditions 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.
Gasoline
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.
1
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 ex-
pansion. Check fuel level on a cold en-
gine before use each day.
Closed
Closed
Oil
Open
After fueling, check oil with unit on level
surface. If oil is not up to full mark on dip-
stick, add oil (see maintenance label).
. To improve cold weather starting:
Full
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
802 511-A
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4-5. Engine Prestart Checks (Honda-Powered Units)
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.
1/2 in
(13 mm)
. Follow run-in procedure in en-
Full
gine manual.
1
Fuel Valve
Open valve.
Gasoline
. 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 mainte-
nance 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 main-
tenance label).
1
. To improve cold weather
starting:
Open
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Full
802 094-A
4-6. Connecting The Battery (Electric-Start Models Only)
Y
Turn Engine Switch to Off
(electric-startmodels only).
Y
Connect negative (−)
cable last.
−
+
Tools Needed:
3/8, 1/2 in
802 524 / Ref. S-0756-D
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4-7. Connecting To Weld Output Terminals
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
1
2
Tools Needed:
3/4 in
196 914 / 495 178
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Stop engine before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95)
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
* 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.
2
( ) = mm for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
TM-499 Page 11
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SECTION 5 − OPERATING THE WELDING GENERATOR
5-1. Controls (Kohler-Powered Units)
6
2
3
50 Hz
60 Hz
1
5
7
4
802 511-A / 802 0511 / 495 178
To Start (Electric): open fuel valve (see Sec-
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.
5
6
Engine Hour Meter
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
Welding Range Label
Use label to determine correct weld amper-
age based on electrode size, type, and mate-
rial thickness.
1
Engine Switch
7
Current Control
Y
If engine does not start, let engine
come to a complete stop before at-
tempting restart.
Use switch to open ignition circuit, and to stop
engine.
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to deter-
mine correct size electrode for material thick-
ness. Select electrode type and set current
control to corresponding amperage range.
Adjust control to obtain desired weld
performance.
2
Throttle Control Lever
4
Starter Handle
To Start (Recoil): open fuel valve (see Sec-
and pull starter handle. Open choke as engine
warms.
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.
EXAMPLE:
To Stop: turn engine switch to Off.
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
3
Choke Control Lever
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Use lever to change engine air/fuel mix. Move
lever to right if starting a cold engine. Move le-
ver to left if starting a warm engine.
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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.
Use label to determine correct weld amper-
age based on electrode size, type, and mate-
rial thickness.
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
7
Current Control
1
Engine Switch
To Start (Electric): open fuel valve, move
throttle lever to Idle, set choke, and turn en-
gine switch to Start position. Open choke as
engine warms.
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 en-
gine.
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to deter-
mine correct size electrode for material thick-
ness. Select electrode type and set current
control to corresponding amperage range on
nameplate. Adjust control within selected
range to obtain desired weld performance.
Y
If engine does not start, let engine
come to a complete stop before at-
tempting restart.
2
Throttle Control Lever
Use lever to select engine speed. Use 50 Hz
or 60 Hz position for generator power. Use 60 To Stop: turn engine switch to Off.
Hz position for maximum weld output.
EXAMPLE:
. Always close fuel valve after stopping
3
Choke Control Lever
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
Use lever to change engine air/fuel mix. Move
lever to left if starting a cold engine. Move le-
ver to right if starting a warm engine.
5
6
Engine Hour Meter
4
Starter Handle (Recoil-Start Models
Only)
Welding Range Label
Notes
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SECTION 6 − OPERATING AUXILIARY EQUIPMENT
The welding generator provides power while welding and with the Current control
NOTE
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)
4
1
2
3
5
495 218
Y
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
RC1 supplies 60 Hz single-phase power at
weld/powerspeed. Maximum output is 3.5
kVA/kW.
CB1 protects RC1 from overload. If CB1
opens, RC1 does not work.
5
Circuit Breakers CB2 And CB3
Power is still present at the 240 volt
receptacle when only one circuit
breaker trips.
2
120 V 20 A AC Duplex Receptacle
RC2
CB2 protects RC2 and CB3 protects RC3
from overload. If a circuit breaker opens,
the receptacle does not work.
3
120 V 20 A AC Duplex Receptacle
RC3
Unplug power cord before attempt-
ing to service accessories or tools.
. Press button to reset circuit breaker.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.
Combinedoutput of all receptacles limited
to 6 kVA/kW rating of the generator. (See
Generator Power Guidelines in Owner’s
Manual.)
. Generator power decreases as weld
current increases.
. Each receptacle of the duplex can pro-
Set Amperage control at max. for full
generatorpower.
vide 15A/1800W.
EXAMPLE:If 10 A is drawn from each 120
volt duplex receptacle, only 9 A is available
from the 120 V twistlock receptacle.
. Do not parallel the two 120V duplex
. Place throttle lever in Run position (far
receptacles.
right) for generator power.
2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/
KW.
1
120 V AC Twistlock Receptacle RC1
4
Circuit Breaker CB1
TM-499 Page 15
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6-2. Optional Generator Power Panels
Generator Power Panel 495 315
(USA)
Generator Power Panel 495 219
(USA)
Generator Power Panel 495 278
Generator Power Panel 495 253 Generator Power Panel 495 288
(Canada−CSA)
(South Africa)
(South America)
Generator Power Panel 495 289
(Australia)
Generator Power Panel 495 290
(Europe)
Generator Power Panel 495 283
(S.E. Asia)
Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277
Y
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
Power may still be present at a re-
ceptacle when a circuit breaker
trips.
. Generator power decreases as weld
. Place throttle lever in Run position (far
current increases.
right) for generator power.
Circuit breakers protect the generator from
overload.
Set Amperage control at max. for full
generatorpower.
. Press button to reset circuit breaker.
Unplug power cord before attempt-
ing to service accessories or tools.
TM-499 Page 16
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6-3. Generator Power Panel Ratings
Unless otherwise stated, the rating of duplex outlets is the combined load of all
receptacles.
NOTE
Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)
Panel
495 278
(Canada-
CSA)
Panel
495 288
(South
Panel
495 218
(USA)
Panel
495 315
(USA)
Panel
495 219
(USA)
Panel
Panel
Panel
495 290
(Europe)
Panel
Protected
Receptacle
495 253
495 289
495 283
By
(S. Africa)
(Australia)
(S.E. Asia)
America)
60 Hz
60 Hz
60 Hz
60 Hz
50 Hz
50 Hz
50 Hz
50 Hz
50 Hz
25A/
5500W
See
25A/
5500W
See
240 V
CB1,2
CB1,2
Twist Lock
Note 2
Note 2
15A/
3600W
See
240 V
Duplex
15A/
3600W
Note 2
240 V
15A/
3600W
CB3,4
CB1
Duplex
230 V
Single
15A/
3600W
15A/
3600W
15A/
3600W
230 V
Single
15A/
3600W
15A/
3600W
15A/
3600W
CB2
230 V
Single
15A/
CB1,2
CB3,4
CB1
3600W
230 V
Single
15A/
3600W
120 V
Twist Lock
30A/
3500W
30A/
3600W
See
120 V
Duplex
CB1,3/
CB2,4
Note 1
120 V
20A/
CB2
CB3
Duplex
2400W
20A/
2400W
See
20A/
2400W
See
120 V
Duplex
20A/
2400W
Note 3
Note 3
20A/
2400W
See
20A/
2400W
See
120 V
Duplex
CB4
Note 3
Note 3
Total
Power NOT
to exceed
5500W
5500W
5500W
5500W
5000W
5000W
5000W
5000W
5000W
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.
For example, for the 495 218 Generator Power Panel,
Calculating total power provided by generator.
(See Generator Power Guidelines in Owner’s Manual.)
120V, 3000W heater
120V, 10A chain saw
120V, 500W halogen lamp
Total
3000W
1200W
500W
Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 5500W.
4700W
This loading is OK.
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.
120V, 3000W heater
120V, 10A chain saw
120V, 5A router
3000W
1200W
600W
120V, 1000W halogen lamp
Total
1000W
5800W
watts = volts x amps
This loading is not OK.
It exceeds 5500W.
TM-499 Page 17
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6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
2
1
1
Plug Wired For 120/240 V,
3-Wire Load
3
When wired for 120 V loads, each du-
plex receptacle shares a load with
one half of the 240 V receptacle.
Tools Needed:
4
2
3
4
5
6
Neutral (Silver) Terminal
Load 1 (Brass) Terminal
Load 2 (Brass) Terminal
Ground (Green) Terminal
Cord Grip
120V
240 V
6
5
120 V
Strip cord jacket back enough to sep-
arate 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
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
NOTE
7-1. Maintenance Label
°C
+40
°F
+104
ENGINE MAINTENANCE
100 h
+30
+20
+10
0
+86
+59
+32
-10
8 h
-10
-15
-20
SG-SF/CC-CD
1.1 l (1.2 US qt,
1.94 lmp qt)
Unleaded
86 + Octane
6.5 l (1.7 US Gal,
11.4 lmp pt)
50 h
0.7 − 0.8 mm
(0.028 − 0.031 in)
200 h
Ref. S-175 679-A
TM-499 Page 18
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7-2. Routine Maintenance
Y
Stop engine before maintaining.
. See Engine Manual and Maintenance Label. Ser-
Recycle
engine
fluids.
vice more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8 h
20 h
Check and clean
spark arrestor screen.
See engine manual.
Check fluid
levels. See
Section 4-4
or 4-5
Wipe up spills.
50 h
Service air cleaner
element. See engine
manual.
Clean and
tighten weld
terminals.
100 h
Check
spark
plugs.
Change oil. See
engine manual and
maintenancelabel.
Clean and tighten battery
connections (Electric
-Start models only).
Clean Fuel
sediment cup.
200 h
Clean fuel
tank and
strainer.
Replace
unreadable
labels.
300 h
Check valve
clearance.*
500 h
Repair or
replace cracked
cables.
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
TM-499 Page 19
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7-3. Overload Protection (Honda-Powered Units)
1
Ignition Circuit Breaker
(Electric-Start Models Only)
The circuit breaker protects the en-
gine 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).
1
Ref. 802 094-A
7-4. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
2000 150 rpm
Start engine and run until warm.
Weld/Power Speed
Adjustment
3720 50 rpm (60 Hz)
3250 50 rpm (50 Hz)
1
2
Throttle Control Lever
Adjustment Screw
Move lever to Run (far right) posi-
tion. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To de-
crease speed, turn screw in (clock-
wise).
Tools Needed:
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 (counter-
clockwise).
Y
Stop engine. Close fuel
valve.
Top View
Top View
3
2
1
802 511-A / Kohler Dwg.
TM-499 Page 20
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7-5. Adjusting Engine Speed (Honda-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
1400 150 rpm
Start engine and run until warm.
Weld/Power Speed
Adjustment
3720 50 rpm (60 Hz)
3250 50 rpm (50 Hz)
1
2
Throttle Control Lever
Adjustment Screw
Move lever to Run (60 Hz) position.
Turn screw and move lever until en-
gine runs at weld/power speed.
Idle Speed Adjustment
3
4
Pilot Screw
Throttle Stop Screw
Move lever to idle position. Turn pi-
lot screw until engine runs at high-
est 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.
2
1
4
3
Tools Needed:
1/4, 3/8 in
802 097-A
TM-499 Page 21
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SECTION 8 − THEORY OF OPERATION
1
Engine
8
Supplies force to turn revolving
fields.
Generator
Power AC
Receptacles
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.
7
Generator Power
Circuit
3
Stator Windings
Breakers
Supply power to exciter, generator
power, and weld circuits.
4
Integrated Rectifier SR1
1
2
3
Changes ac output of stator
windings to dc to supply excitation
current to the exciter revolving field.
Generator Power
Stator Windings
Exciter
Revolving
Field
(Rotor)
Engine
5
Control Board PC1
Adjusts weld output by changing
revolving field current after
comparing feedback to amperage
setting of R1.
4
Uses current feedback signal for
foldback circuit to prevent stator
failure from short-circuit conditions.
Integrated
Rectifier
SR1
Use voltage feedback signal to
maintain open-circuit and genera-
tor 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.
5
7
Generator Power Circuit
Breakers
Control
Board
PC1
Protect ac receptacles from over-
load.
8
Generator Power AC
Receptacles
Provide connection points and
power for auxiliary equipment.
6
Current
Control R1
TM-499 Page 22
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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 (−)
9
Weld Output Terminals
Provide weld output.
Main Rectifier
SR2
10
Suppressor
VR1/R2
Voltage Feedback Signal
Voltage Feedback Signal
12
11
Stabilizer
L1
Shunt
13
HF Filter
Board
PC2
Current Feedback Signal
14
14
Positive (+)
Weld Output
Terminal
Negative (−)
Weld Output
Terminal
Electrode
Work
AC Or DC Control Circuits
Weld Current Circuit
Mechanical Coupling
Magnetic Coupling
TM-499 Page 23
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SECTION 9 − EXPLANATION OF ELECTRICAL PARTS
elect_parts 7/04
9-1. Safety Precautions − Read Before Using This Guide
Y
WARNING: ELECTRIC SHOCK can kill.
D
D
D
D
Disconnect input power or stop engine before servicing.
Do not touch live electrical parts.
Do not operate machines with covers removed.
Have only qualified persons install, use, or service equipment.
PART NAME
BATTERY
FUNCTION
PICTURE
CIRCUIT SYMBOL
+
A source of DC voltage. Typically used in
Engine Driven equipment.
BRUSHES/SLIP
RINGS
Components that allow electrical connections
between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
CAPACITOR
CHASSIS
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.
POLARIZED NON-POL.
+
C1
C1
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
CB1
circuit breaker can be reset.
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
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PART NAME
CLAMP
FUNCTION
PICTURE
CIRCUIT SYMBOL
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.
COIL
W
W
NRM OPEN
POINTS
CT1
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.
OR
CT1
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.
FM
DIODE
A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
D1
FAN MOTOR
This device provides cooling of the internal
parts of a welding power source.
FM
F1
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.
GS1
OR
WS1
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.
HD1
TM-499 Page 25
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PART NAME
IGBT
FUNCTION
PICTURE
CIRCUIT SYMBOL
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.
C1
G1 (B1)
E1
INTEGRATED
BRIDGE
RECTIFIER
An arrangement of four diodes used to
change AC to DC.
+
AC
+
AC
AC
−
AC
_
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.
U1
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.
TE1
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.
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”.
MA1
METER
A measuring device. A “voltmeter” is a good
example.
V = voltmeter
A = ammeter
V
HM = hour
meter
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.
D
S
G
AS
TM-499 Page 26
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PART NAME
MOTOR
FUNCTION
PICTURE
CIRCUIT SYMBOL
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.
M1
M1
= DC
= AC
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.
+
_
A1
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.
OC1
PILOT LIGHT
A light located on the front panel which
indicates if the machine is on or off.
1
PL
POTENTIOMETER Both devices have a moveable brush that
OR
RHEOSTAT
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,
R1
CW = CLOCKWISE
CCW =COUNTER-
CLOCKWISE
inductance, etc.
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.
MALE
FEMALE
PLG =
LOOSE
PLG1
RC1
RECEPTACLE
A connection device that is mounted or fixed.
Just like a plug, the terminals can be either
male or female.
MALE
FEMALE
RC =
MOUNTED
COIL
CR1
RELAY−−COIL AND This is an electromechanical device whose
CONTACTS, contacts change state (the normally open
NORMALLY OPEN points close and the normally closed points
AND NORMALLY
CLOSED
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.
CR1
CR1
NRM OPEN NRM CLOSED
POINTS
POINTS
R1
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.
FIXED
R1
FIXED TAPPED
RIBBON CABLE
A connection device where the wires are laid
out flat. Usually to connect circuits from one
PC board to another PC board.
26-CONDUCTOR
CABLE
RC54
RC44
TM-499 Page 27
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PART NAME
SCR
FUNCTION
PICTURE
CIRCUIT SYMBOL
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.
K
G
A
SHUNT
A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
SHUNT
SNUBBER
A device used to absorb voltage spikes,
sometimes found connected across the
points of a relay.
SN1
G
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.
Z1
L1
SWITCH
A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
SPST
DPST
SPDT
DPDT
A multi-pole switch will use dashed lines to
connect poles.
SPST = Single Pole Single Throw
SPDT = Single Pole Double Throw
DPST = Double Pole Single Throw
DPDT = Double Pole Double Throw
MOMENTARY
SWITCH
A switch that “springs back” to its original
position.
S1
LIMIT SWITCH
A switch mounted in the path of a moving
object and actuated by its passage.
NRM OPEN
S1
NRM
CLOSED
S1
NRM
PUSH BUTTON
SWITCH
A switch in which a button must be
depressed each time the contacts are to be
opened or closed.
NRM
CLOSED
PB1
OPEN
PB1
ROTARY SWITCH
TM-499 Page 28
A switch in which its shaft must be rotated to
actuate the contacts.
S1
S1
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PART NAME
FUNCTION
PICTURE
CIRCUIT SYMBOL
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
PRESSURE
SWITCH
A change in the pressure of a gas or liquid
will actuate this switch.
S1
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
TEMPERATURE
SWITCH
Typically used to protect engines, this switch
is actuated by heat.
S1
S1
WATER FLOW
SWITCH
A switch that is actuated by the flow of a
liquid. Typically used to protect
“water-cooled” torches.
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
TERMINAL
ASSEMBLY
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.
TE1
TE1
TERMINAL STRIP
THERMISTOR
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
42 42 104 105 74
1T
A
B
C
D
E
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
104
105
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.
RT1
OR
TH1
THERMOSTAT,
This is a switch that closes its normally open
NORMALLY OPEN contacts (or opens its normally closed
TP1
TP1
AND 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.
NRM CLOSED
NRM OPEN
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.
Q1
B
Q1
B
C
E
C
E
NPN
PNP
TM-499 Page 29
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PART NAME
FUNCTION
PICTURE
CIRCUIT SYMBOL
TRANSFORMER
A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
IRON
CORE
T1
FERRITE
CORE
T1
T1
AIR
CORE
TRIAC
An electronic AC switch. It is turned on by a
gate signal similar to an SCR.
Q1
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.
RED
WHT
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.
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
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SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
A.
Welding
values and Section 13 and following
for parts location.
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 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 con-
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.
Service air cleaner according to engine manual.
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
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Trouble
Remedy
High weld output.
Check Current Control R1 setting.
Check resistance and connections of suppressor VR1/R2. R2 is 1000 ohms 5%. Replace VR1/R2 if
necessary.
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.
Check Current Control R1 setting.
Erratic weld output.
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 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 ener-
gized.
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.
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 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 con-
trol 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 gener-
ator power leads 1 and 3, and leads 2 and 4. Replace stator if necessary.
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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.
Move throttle lever to Run (use 50 Hz position for 50 Hz equipment).
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 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 control board PC1 and connections, and replace if necessary. PC1 LED lights when board is ener-
gized.
C.
Engine
Trouble
Remedy
Engine will not crank (electric-start
models only).
Reset ignition circuit breaker.
Check battery voltage.
Check battery connections and tighten if necessary.
Check engine ignition circuit, and replace components if necessary.
Engine will not start.
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.
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Trouble
Remedy
Engine stopped during normal
operation.
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 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 (elec- Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
tric-start models only).
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Unstable or sluggish engine speeds.
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
TM-499 Page 34
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
TM-499 Page 35
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waveforms A,B,C,D
V5
R6
V6, A, B
C, D
V3, R5
V1,
R3
V2,
R4
See Section 8 for
PC2 information
I1
V4
R1
V10
R8
See also
Section 10-5
for PC1 data
V9,
R7
V7
V8
V11
R2
V9,
R7
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197 857-E
TM-499 Page 37
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Amperage Readings
a) Tolerance − 5% unless specified
Voltage Readings
a) Tolerance − 10% unless specified
b) Condition
−
70°F (21°C); cold
b) Condition
−
70°F (21°C); cold
machine (no warm-up); no load
machine (no warm-up); no load
c) Weld/power rpm unless specified
I1
1.8 amps dc (60 Hz)
2.3 amps dc (50 Hz)
d) Reference − single arrow: reference
to circuit common (lead 11); double
arrow: reference to points indicated
Resistance Values
V1
V2
V3
V4
V5
V6
122 volts ac 5% (60 Hz)
110 volts ac 5% (50 Hz)
a) Tolerance − 10% unless specified
122 volts ac 5% (60 Hz)
110 volts ac 5% (50 Hz)
b) Condition
−
70°F (21°C); cold
machine (no warm-up)
76 volts ac (60 Hz)
69 volts ac (50 Hz)
d) Stop engine before checking
resistance
50 volts dc (60 Hz)
70 volts dc (50 Hz)
At 25 volt, 100 ampere weld load:
Less than 1 volt dc (60 and 50 Hz)
R1
27 ohms
R2
20 ohms (Kohler Only)
Less than 1 ohm
68 volts dc (60 Hz)
62 volts dc (50 Hz)
R3 thru R8
V7
V8
V9
0 − 10 volts dc (60 or 50 Hz)
15 volts dc (60 or 50 Hz)
23.5 volts ac (60 Hz)
20.5 volts ac (50 Hz)
V10
V11
200 volts dc (60 Hz)
176 volts dc (50 Hz)
Test Equipment Needed:
18.2 volts ac (60 Hz) − Kohler Only
15.5 volts ac (50 Hz) − Kohler Only
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10-4. Waveforms For Section 10-2
Waveforms shown are for 60 Hertz models;
waveforms for 50 Hertz models are similar.
5 ms 50 V
gnd
A. DC/CC Open-Circuit Voltage, No Load, 60 Hz
5 ms 20 V
gnd
B. 25 Volts DC, 185 Amperes (Resistive Load), 60 Hz
Test Equipment Needed:
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10-5. Control Board PC1 Testing Information
Be sure plugs are secure before
testing. See Section 10-6 for
specific values during testing.
1
2
3
Receptacle RC5
Receptacle RC4
LED1
2
LED1 lights when board is
energized.
3
1
Test Equipment Needed:
802 524 / 198 221-A
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10-6. Control Board PC1 Test Point Values
a) Tolerance
specified
−
10% unless
PC1 Voltage Readings
b) Condition − no load; throttle
lever in 60 Hz position
c) Reference − to circuit common
(RC4-7) unless noted
Receptacle
Pin
Value
RC4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
18 volts ac input with respect to pin 2
18 volts ac input with respect to pin 1
+50 volts dc output with respect to pin 4
−50 volts dc output with respect to pin 3
+200 volts dc input with respect to pin 6
Circuit common
Circuit common (shield) for shunt input
Shunt negative (circuit common)
Shunt positive (less than 1 volt dc input with respect to pin 8 with 100 ampere, 25 volt weld load
RC5
0 volts dc
+15 volts dc input
Circuit common
+10 volts dc output with respect to pin 6
0 to +10 volts dc input from min. to max. of Current Control R1 with respect to pin 6
Circuit common
Weld feedback input; same as negative (−) weld output terminal voltage
0 volts dc
0 volts dc when engine speed is greater than 2800 rpm
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10-7. Replacing Brushes And Cleaning Slip Rings
Y
1
Stop engine.
Generator End Panel
Brush Assembly
Brush Holder
2
3
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.
3
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutatorstone. Remove as little
material as possible.
1/4 in (6 mm)
Or Less − Replace
Y
Stop engine. Close fuel
valve.
7/16 in − 1/2 in
(11 − 12 mm) New
4
2
Install brushes, brush holders, and
brush arm.
Reinstall cover.
1
Tools Needed:
ST-802 524 / ST-801 842
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10-8. Checking Unit Output After Servicing
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
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
2
Y
Stop engine. Close fuel
valve.
Allow engine to cool, and complete
pre-operational checks in table.
1
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Test Equipment Needed:
ST-802 524
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SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
trouble is in stator, rotor, engine or
combinationof these components.
Remove cover. Mark and discon-
nect stator leads.
Disassemble in sequence shown.
Y
Use hoist and lifting strap to
carefully remove engine/
generator assembly.
Tools Needed:
802 524
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11-2. Removing Rotor And Reassembling Generator
Y
Do not damage rotor or sta-
tor windings during this pro-
cedure.
To remove rotor:
Removing 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 lamina-
tions. (turning screw into rotor
forces rotor off engine shaft.)
1
2
Reassembly
3
4
5
6
7
8
9
Brushholder Assembly
Generator End Panel
Bearing Carrier
Rotor Assembly
Stator Assembly
Generator Fan
1 in
7-1/2 in
(25.4 mm)
(191 mm)
Generator Guard
10 Engine Adapter
11 Engine
Cut screwdriver
slot in end of rod.
5/16 in
(8 mm)
24 threads
per inch
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.
Reassembling Generator
11
3
10
9
8
7
Tools Needed:
Torques:
6
.
A
B
95 in lb (10.7 N m)
A
.
5
205 in lb (23.1 N m)
4
B
802 524 / 802 509
TM-499 Page 45
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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.
Circuit
Diagram
Wiring
Diagram
Model
Serial Or Style Number
Welding Generator
LA124002 and following (Kohler)
LA347885 and following (Honda)
197 857-E
197 858-C
201 026-A
Generator Power Panels
Circuit Board PC1
LA124002 and following (Kohler)
LA347885 and following (Honda)
LA124002 and following (Kohler)
LA033425 and following (Honda)
198 222
Circuit Board PC2
LA124002 and following (Kohler)
KH467216 and following (Honda)
SA-148 611-A
The circuits for Honda-powered units were implemented prior to the effective date
of this manual.
NOTE
SA-148 611-A
Figure 12-1. Circuit Diagram For HF Board PC2 Eff. w/ Serial No. LA124002 And Following (Kohler)
Or KH467216 And Following (Honda)
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197 857-E
Figure 12-2. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA347885 And Following (Honda) (1 Of 2)
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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)
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197 858-C
Figure 12-4. Wiring Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)
Or LA347885 And Following (Honda)
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Apply small amount of conductive electric com-
pound (Part No. 603 978) to terminals where
factory-applied compound had been present.
201 026-A
Figure 12-5. Wiring Diagram For Generator Power Panels Eff. w/ Serial No. LA124002 And
Following (Kohler) Or LA347885 And Following (Honda) (1 Of 2)
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Apply small amount of conductive electric com-
pound (Part No. 603 978) to terminals where
factory-applied compound had been present.
201 026-A
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)
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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)
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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
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Eff w/LA124002 Thru LB111747 (Kohler Only)
Item
No.
Dia.
Part
Mkgs.
No.
Description
Quantity
Figure 13-1. Main Assembly
. . . 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
. . . . . . . . . . . . . . . . . . . . . 495 154 . . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
+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
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Eff w/LA124002 Thru LB111747 (Kohler Only)
. Hardware is common and not available unless listed.
8
2
3
5
4
1
6
7
9
10
Generator Power Panel 196 914 (CSA)
Generator Power Panel 495 315
11
13
12
12
14
14
Generator Power Panel 495 289
(Australia)
Generator Power Panel 495 253
(South Africa)
196 921
Figure 13-2. Generator Power Panels
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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
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
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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
Download from Www.Somanuals.com. All Manuals Search And Download.
Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly
. . . 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
. . . . . . . . . . . . . . . . . . . . . 129 527 . . PLUG, weld cable (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
. . . . . . . . . . . . . . . . . . . . *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
. . . 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
. . . . . . . . . . . . . . . . . . . . . 495 154 . . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TM-499 Page 59
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Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . . 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.
TM-499 Page 60
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Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
2
3
4
5
. Hardware is common and not available unless listed.
8
1
9
6
7
10
Generator Power Panel 495 315 (USA)
Generator Power Panel 196 914 (CSA)
11
12
13
12
14
14
Generator Power Panel 495 253
(South Africa)
Generator Power Panel 495 289
(Australia)
21
22
15
17
18
16
19
20
Generator Power Panel 495 219
(USA)
Generator Power Panel 495 290
(Europe)
25
26
23
24
Generator Power Panel 495 288
(S. America)
Generator Power Panel 495 283
(S.E. Asia)
27
28
29
32
33
34
36
30
31
35
Generator Power Panel 495 298
(USA)
Generator Power Panel 495 278
(Canada−CSA)
196 921
Figure 14-2. Generator Power Panels
TM-499 Page 61
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Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 20 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
. . . . . . . . . . . . . . . . . . . . . 605 797 . . PLUG, tw lk 3P3W 20A 125V
. . . 31 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 36 . . . . RC2 . . . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
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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
Download from Www.Somanuals.com. All Manuals Search And Download.
Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly
. . . 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
. . . . . . . . . . . . . . . . . . . . . 129 527 . . PLUG, weld cable (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
. . . . . . . . . . . . . . . . . . . . *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
. . . 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
. . . . . . . . . . . . . . . . . . . . . 495 154 . . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TM-499 Page 65
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Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Continued)
. . . 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.
TM-499 Page 66
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Eff w/LC061261 Thru LC552236 (Kohler & Honda)
3
4
5
6
. Hardware is common and not available unless listed.
7
8
1
2
10
11
9
Generator Power Panel 495 315 (USA)
Generator Power Panel 495 218 (USA)
12
13
14
15
13
15
Generator Power Panel 495 253 (South Africa)
Generator Power Panel 495 289 (Australia)
22
16
18
19
23
17
20
21
Generator Power Panel 495 219 (USA)
Generator Power Panel 495 290 (Europe)
26
27
24
25
Generator Power Panel 495 288 (S. America)
Generator Power Panel 495 283 (S.E. Asia)
28
30
33
35
37
29
34
31
32
36
Generator Power Panel 495 298 (USA)
Generator Power Panel 495 278 (Canada−CSA)
Figure 15-2. Generator Power Panels
TM-499 Page 67
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Eff w/LC061261 Thru LC552236 (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 21 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
. . . . . . . . . . . . . . . . . . . . . 605 797 . . PLUG, tw lk 3P3W 20A 125V
. . . 32 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
Generator Power Panel 495 278 (Canada−CSA)
. . . 33 . . . . . . . . . . . . . . . 495 277 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . CB1 . . . . . 203 095 . . CIRCUIT BREAKER, 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 631 . . COVER, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 630 . . BRACKET, mtg circuit breaker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . RC1 . . . . . 129 067 . . RECEPTACLE, tw lk grd 3P4W 30A 125/250V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 37 . . . . RC2 . . . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
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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
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Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Main Assembly
. . . 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
. . . . . . . . . . . . . . . . . . . . . 129 527 . . PLUG, weld cable (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
. . . . . . . . . . . . . . . . . . . . *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
. . . 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
. . . . . . . . . . . . . . . . . . . . . 495 154 . . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TM-499 Page 71
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Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Main Assembly (Continued)
. . . 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.
TM-499 Page 72
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Eff w/LC552237 And Following (Kohler & Honda)
3
4
5
6
. Hardware is common and not available unless listed.
7
1
2
8
10
11
9
Generator Power Panel 495 315 (USA)
Generator Power Panel 495 218 (USA)
12
13
14
15
13
15
Generator Power Panel 495 253 (South Africa)
Generator Power Panel 495 289 (Australia)
22
16
18
19
23
17
20
21
Generator Power Panel 495 219 (USA)
Generator Power Panel 495 290 (Europe)
26
27
24
25
Generator Power Panel 495 288 (S. America)
Generator Power Panel 495 283 (S.E. Asia)
28
30
33
35
37
29
34
36
31
32
Generator Power Panel 495 298 (USA)
Generator Power Panel 495 278 (Canada−CSA)
Figure 16-2. Generator Power Panels
TM-499 Page 73
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Eff w/LC552237 And Following (Kohler & Honda)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 21 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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
. . . . . . . . . . . . . . . . . . . . . 605 797 . . PLUG, tw lk 3P3W 20A 125V
. . . 32 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
Generator Power Panel 495 278 (Canada−CSA)
. . . 33 . . . . . . . . . . . . . . . 495 277 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . CB1 . . . . . 203 095 . . CIRCUIT BREAKER, 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 631 . . COVER, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 630 . . BRACKET, mtg circuit breaker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . RC1 . . . . . 129 067 . . RECEPTACLE, tw lk grd 3P4W 30A 125/250V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 37 . . . . RC2 . . . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
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 74
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Notes
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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
PRINTED IN USA
2004 Miller Electric Mfg. Co.
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