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Miller Electric Blue Star 6000 Technical Manual Download Page 66

Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)

TM-499 Page 62

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 14-2. Generator Power Panels (Figure 14-1, Item 39)

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.

Summary of Contents for Blue Star 6000

Page 1: ...Description Stick SMAW Welding Engine Driven Welding Generator TM 499C August 2004 Eff w Serial Number LA124002 Kohler Eff w Serial Number LB086216 Honda Visit our website at www MillerWelds com Blue Star 6000 R ...

Page 2: ...5 1 Controls Kohler Powered Units 12 5 2 Controls Honda Powered Units See Section 5 3 13 5 3 Description Of Controls Honda Powered Units See Section 5 2 14 SECTION 6 OPERATING AUXILIARY EQUIPMENT 15 6 1 Generator Power Panel 495 218 USA 15 6 2 Optional Generator Power Panels 16 6 3 Generator Power Panel Ratings 17 6 4 Wiring Instructions For Optional 120 240 Volt Twistlock Plug NEMA L14 30P 18 SEC...

Page 3: ...ng Generator 45 SECTION 12 ELECTRICAL DIAGRAMS 46 SECTION 13 PARTS LIST FOR LA124002 THRU LB111747 KOHLER ONLY 54 SECTION 14 PARTS LIST FOR LB111748 THRU LC061260 KOHLER AND LB086216 THRU LC061260 HONDA 58 SECTION 15 PARTS LIST FOR LC061261 THRU LC552236 KOHLER HONDA 64 SECTION 16 PARTS LIST FOR LC552237 AND FOLLOWING 70 ...

Page 4: ......

Page 5: ... rotors D Have only qualified people remove guards or covers for maintenance and troubleshootingas necessary D Keep hands hair loose clothing and tools away from mov ing parts D Before working on generator remove spark plugs or injec tors to keep engine from kicking back or starting D Block flywheel so that it will not turn while working on gener ator components D Reinstall panels or guards and cl...

Page 6: ...rference OVERUSE can cause OVERHEATING D Allow cooling period follow rated duty cycle D Reduce current or reduce duty cycle before starting to weld again D Do not block or filter airflow to unit READ INSTRUCTIONS D Use Testing Booklet Part No 150 853 when servicing this unit D Consult the Owner s Manual for welding safety precautions D Use only genuine replacement parts D Reinstall injectors and b...

Page 7: ...al NOTE 3 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine CC DC 40 180 A 60 Hz 40 160 A 50 Hz 180 A 25 V 30 Duty Cycle 130 A 25 V 60 Duty Cycle 100 A 25 V 100 Duty Cycle 80 60 Hz 70 50 Hz Single Phase 6 kVA kW Peak 5 5 kVA kW Continuous 50 25 A 110 220 V AC 50 Hz 120 240 V AC 60 Hz K...

Page 8: ... 10 1 2 in 268 mm Y Do not move or operate unit where it could tip C 13 45 64 in 348 mm A D 22 3 4 in 577 mm A E 1 3 4 in 44 mm C F 19 1 2 in 495 mm G 13 32 in 10 mm Dia 15 15 Weight 4 G 15 1 15 15 Kohler 265 lb 120 kg 4 Holes G 15 15 Honda Electric Start Model 278 lb 126 kg Honda Recoil Start Model 253 lb 114 kg 802 096 Holes Engine End F E 802 524 A 3 3 Fuel Consumption Kohler Powered Units 198 ...

Page 9: ...ed Units 802 122 Continuous Welding 3 5 Duty Cycle 802 093 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 100 Duty Cycle at 100 Amperes CC DC ...

Page 10: ... power curves show the ac power available in amperes at the receptacles A 60 Hz Model B 50 Hz Model 0 25 50 75 100 125 150 175 200 225 250 0 5 10 15 20 25 30 35 LOAD AMPS LOAD VOLTS 0 25 50 75 100 125 150 175 200 225 250 0 5 10 15 20 25 30 35 LOAD AMPS LOAD VOLTS ...

Page 11: ...ut capabilities of the welding generator Curves of all other settings fall between the curves shown A 60 Hz Model B 50 Hz Model 0 10 20 30 40 50 60 70 80 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS LOAD VOLTS MIN MID MAX 0 10 20 30 40 50 60 70 80 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS LOAD VOLTS MIN MID MAX ...

Page 12: ...DOT and other applicable codes 4 2 Grounding Generator To Truck Or Trailer Frame install1 10 00 Ref 151 556 S 0854 Y Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire Y If unit does not have GFCI re ceptacles use G...

Page 13: ...w 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 1 Fuel Valve Open valve by turning lever to vertical position Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first ti...

Page 14: ...ng 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 To improve cold weather starting Keep battery in good condition Store battery in...

Page 15: ...nnectingto weld out put terminals Y Do not use worn dam aged undersized or poorly spliced cables Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 This ch...

Page 16: ...ing to start engine Y If engine does not start let engine come to a complete stop before at tempting restart 4 Starter Handle To Start Recoil open fuel valve see Sec tion4 4 move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flood...

Page 17: ...TM 499 Page 13 5 2 Controls Honda Powered Units See Section 5 3 802 094 A 802 095 495 187 Recoil Start Electric Start 60 Hz 50 Hz 1 3 6 2 1 4 5 7 ...

Page 18: ...hoke as engine warms 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 Y If engine does not start let engine come to a complete stop before at tempting restart To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make...

Page 19: ...on far right for generator power 1 120 V AC Twistlock Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 3 5 kVA kW 2 120 V 20 A AC Duplex Receptacle RC2 3 120 V 20 A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW Each receptacle of the duplex can pro vide 15A 1800W Do not...

Page 20: ...ll be present at a re ceptacle when a circuit breaker trips Unplug power cord before attempt ing to service accessories or tools Generator power decreases as weld current increases Set Amperage control at max for full generator power Place throttle lever in Run position far right for generator power Circuit breakers protect the generator from overload Press button to reset circuit breaker Generato...

Page 21: ...120 V Duplex CB3 20A 2400W 20A 2400W See Note 3 20A 2400W See Note 3 120 V Duplex CB4 20A 2400W See Note 3 20A 2400W See Note 3 Total Power NOT to exceed 5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W For example for the 495 218 Generator Power Panel 120V 3000W heater 3000W 120V 10A chain saw 1200W 120V 500W halogen lamp 500W Total 4700W This loading is OK 120V 3000W heater 3000W 120V 10A c...

Page 22: ...onductors 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 1 3 2 4 Tools Needed 5 6 120 V 240 V 120V 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 Ref S 17...

Page 23: ...ne manual 50 h Clean and tighten weld terminals Service air cleaner element See engine manual 100 h Change oil See engine manual and maintenancelabel Check spark plugs Clean and tighten battery connections Electric Start models only Clean Fuel sediment cup 200 h Replace unreadable labels Clean fuel tank and strainer 300 h Check valve clearance 500 h Repair or replace cracked cables Service welding...

Page 24: ...ng engine check engine speeds See table for proper no load speeds If necessary adjust speeds as follows Start engine and run until warm Weld Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far right 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 Idle Speed Adjustme...

Page 25: ... Lever 2 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 Pilot Screw 4 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 1 4 3 8 in Tool...

Page 26: ...failure from short circuit conditions 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 7 Generator Power Circuit Breakers Prote...

Page 27: ...ard PC2 Protects unit from high frequency 14 Positive And Negative Weld Output Terminals Provide weld output AC Or DC Control Circuits Mechanical Coupling Weld Current Circuit Magnetic Coupling Positive Weld Output Terminal Negative Weld Output Terminal Electrode Work 14 14 Main Rectifier HF Filter SR2 Board PC2 Voltage Feedback Signal Current Feedback Signal Shunt 9 12 13 Suppressor VR1 R2 10 Sta...

Page 28: ...er source Smaller disk capacitors can be used for HF protection C1 C1 POLARIZED NON POL CHASSIS The green ground wire of a primary cord is connected to the machine frame chassis for safety Also you may find many HF bypass capacitors connected to chassis to reduce High Frequency interference Expect to see this symbol used numerous times in circuit diagrams The picture shown here is from an Engine D...

Page 29: ...en 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 i...

Page 30: ... 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...

Page 31: ... welding parameters such as wire speed preflow time voltage inductance etc CW CLOCKWISE R1 CCW COUNTER CLOCKWISE PLUG A connection device that hangs loose with wires coming out the back of it Please note that the plug terminals can be either male or female PLG1 PLG LOOSE MALE FEMALE RECEPTACLE A connection device that is mounted or fixed Just like a plug the terminals can be either male or female ...

Page 32: ...lizer 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 ...

Page 33: ...al checks when troubleshooting Notice the jumper link connecting terminals A and B together A B C D E 1T 42 42 104 105 74 104 105 THERMISTOR A thermally sensitive resistor There are two types of thermistor PTC Positive Temperature Coefficient and NTC Negative Temperature Coefficient A PTC thermistor s resistance will increase as the temperature goes up where as an NTC thermistor s resistance will ...

Page 34: ... 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 CONNECTIO...

Page 35: ...nect 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 Contr...

Page 36: ...k 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 r...

Page 37: ...nd replace if necessary Disconnect leads 3 and 4 from brushes and check continuity across slip rings Replace rotor if necessary Erratic power output at ac receptacles Check fuel level Check receptacle wiring and connections Check throttle governor linkage for smooth non binding operation Service air cleaner according to engine manual Check engine speed and adjust if necessary see Section 7 4 or 7 ...

Page 38: ...t operating angle Low oil level shutdown switch may stop engine if unit is tilted Battery discharges between uses elec tric start models only Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Unstable or sluggish en...

Page 39: ...TM 499 Page 35 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 40: ...cuit Diagram For Welding Generator Use With Section 10 3 V6 A B See Section 10 4 for waveforms A B C D See also Section 10 5 for PC1 data V5 V4 V3 R5 V8 V7 R6 R1 See Section 8 for PC2 information C D V1 R3 V2 R4 V10 R8 I1 R2 V11 V9 R7 V9 R7 ...

Page 41: ...TM 499 Page 37 197 857 E ...

Page 42: ...5 At 25 volt 100 ampere weld load Less than 1 volt dc 60 and 50 Hz V6 68 volts dc 60 Hz 62 volts dc 50 Hz V7 0 10 volts dc 60 or 50 Hz V8 15 volts dc 60 or 50 Hz V9 23 5 volts ac 60 Hz 20 5 volts ac 50 Hz V10 200 volts dc 60 Hz 176 volts dc 50 Hz V11 18 2 volts ac 60 Hz Kohler Only 15 5 volts ac 50 Hz Kohler Only Resistance Values a Tolerance 10 unless specified b Condition 70 F 21 C cold machine ...

Page 43: ... Section 10 2 Test Equipment Needed 5 ms 50 V A DC CC Open Circuit Voltage No Load 60 Hz 5 ms 20 V B 25 Volts DC 185 Amperes Resistive Load 60 Hz gnd gnd Waveforms shown are for 60 Hertz models waveforms for 50 Hertz models are similar ...

Page 44: ...C1 Testing Information 802 524 198 221 A Be sure plugs are secure before testing See Section 10 6 for specific values during testing 1 Receptacle RC5 2 Receptacle RC4 3 LED1 LED1 lights when board is energized Test Equipment Needed 2 1 3 ...

Page 45: ...ith respect to pin 3 5 200 volts dc input with respect to pin 6 6 Circuit common 7 Circuit common shield for shunt input 8 Shunt negative circuit common 9 Shunt positive less than 1 volt dc input with respect to pin 8 with 100 ampere 25 volt weld load RC5 1 0 volts dc 2 15 volts dc input 3 Circuit common 4 10 volts dc output with respect to pin 6 5 0 to 10 volts dc input from min to max of Current...

Page 46: ...ged or if brush is at or near minimum length 5 Slip Rings Visually inspect slip rings Under normal use rings turn dark brown If slip rings are corroded or surface is uneven insulate brush leads start engine and clean rings with a commutatorstone Remove as little material as possible Y Stop engine Close fuel valve Install brushes brush holders and brush arm Reinstall cover 3 1 4 in 6 mm Or Less Rep...

Page 47: ...e should be 10 above receptacle rating on nameplate EXAMPLE Correct no load voltage for a 120 volt receptacle should be 132 volts ac If generator power or weld output voltage is incorrect adjust engine speed see Section 7 4 or 7 5 Y Stop engine Close fuel valve Allow engine to cool and complete pre operational checks in table 1 Test Equipment Needed Pre Operational Checks Wipe engine surfaces clea...

Page 48: ... Use Section 10 2 to determine if 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 Go to Section 11 2 Tools Needed ...

Page 49: ...g rotor lamina tions turning screw into rotor forces rotor off engine shaft Reassembly 3 Brushholder Assembly 4 Generator End Panel 5 Bearing Carrier 6 Rotor Assembly 7 Stator Assembly 8 Generator Fan 9 Generator Guard 10 Engine Adapter 11 Engine Reinstall engine and generator parts using torque values in table Reconnect all leads Use cable ties to secure leads in wiring harness and away from movi...

Page 50: ...nerator LA124002 and following Kohler LA347885 and following Honda 197 857 E 197 858 C Generator Power Panels LA124002 and following Kohler LA347885 and following Honda 201 026 A Circuit Board PC1 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 impl...

Page 51: ...TM 499 Page 47 197 857 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 ...

Page 52: ...TM 499 Page 48 197 857 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 ...

Page 53: ...TM 499 Page 49 197 858 C Figure 12 4 Wiring Diagram For Welding Generator Eff w Serial No LA124002 And Following Kohler Or LA347885 And Following Honda ...

Page 54: ...f conductive electric com pound Part No 603 978 to terminals where factory applied compound had been present Figure 12 5 Wiring Diagram For Generator Power Panels Eff w Serial No LA124002 And Following Kohler Or LA347885 And Following Honda 1 Of 2 ...

Page 55: ...f conductive electric com pound Part No 603 978 to terminals where factory applied compound had been present Figure 12 6 Wiring Diagram For Generator Power Panels Eff w Serial No LA124002 And Following Kohler Or LA347885 And Following Honda 2 Of 2 ...

Page 56: ...TM 499 Page 52 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 ...

Page 57: ...Processes Description Stick SMAW Welding Engine Driven Welding Generator TM 499C August 2004 Eff w LA124002 Thru LB111747 Kohler Only For OM 499 197 850 Revisions Thru B ...

Page 58: ...2 THRU LB111747 KOHLER ONLY 802 509 Hardware is common and not available unless listed 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 Figure 13 1 Main Assembly ...

Page 59: ...g 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 mod...

Page 60: ...n 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 B...

Page 61: ...Processes Description Stick SMAW Welding Engine Driven Welding Generator TM 499C August 2004 Eff w LB111748 Thru LC061260 Kohler Eff w LB086216 Thru LC061260 Honda For OM 499 197 850 Revision C ...

Page 62: ...OHLER AND LB086216 THRU LC061260 HONDA 802 509 A Hardware is common and not available unless listed 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 49 Figure 14 1 Main Assembly ...

Page 63: ...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 RO...

Page 64: ...ESISTOR 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 e...

Page 65: ...ator Power Panel 495 278 Canada CSA Generator Power Panel 495 253 South Africa Generator Power Panel 495 289 Australia Generator Power Panel 196 914 CSA 8 9 10 15 16 32 11 13 12 12 14 14 21 22 23 24 Generator Power Panel 495 290 Europe Generator Power Panel 495 288 S America 28 29 30 31 Generator Power Panel 495 283 S E Asia Generator Power Panel 495 298 USA 25 26 27 17 18 20 19 34 35 36 33 Figure...

Page 66: ... 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 C...

Page 67: ...Processes Description Stick SMAW Welding Engine Driven Welding Generator TM 499C August 2004 Eff w LC061261 Thru LC552236 Kohler Honda For OM 499 197 850 Revisions D Thru F ...

Page 68: ...HRU LC552236 KOHLER HONDA 802 509 A Hardware is common and not available unless listed 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 Figure 15 1 Main Assembly ...

Page 69: ...ohler 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...

Page 70: ...5 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 you...

Page 71: ... CSA Generator Power Panel 495 253 South Africa Generator Power Panel 495 289 Australia Generator Power Panel 495 218 USA 7 8 10 16 17 33 12 14 13 13 15 15 22 23 24 25 Generator Power Panel 495 290 Europe Generator Power Panel 495 288 S America 29 30 31 32 Generator Power Panel 495 283 S E Asia Generator Power Panel 495 298 USA 26 27 28 18 19 21 20 35 36 37 34 4 5 3 6 1 2 9 11 Figure 15 2 Generato...

Page 72: ...90 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 15...

Page 73: ...Processes Description Stick SMAW Welding Engine Driven Welding Generator TM 499C August 2004 Eff w LC552237 And Following Kohler Honda For OM 499 197 850 Revisions G And H ...

Page 74: ...2237 AND FOLLOWING 802 509 A Hardware is common and not available unless listed 7 32 33 34 31 28 29 30 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 24 Figure 16 1 Main Assembly ...

Page 75: ...3 956 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 FA...

Page 76: ...bly 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 th...

Page 77: ... CSA Generator Power Panel 495 253 South Africa Generator Power Panel 495 289 Australia Generator Power Panel 495 218 USA 7 8 10 16 17 33 12 14 13 13 15 15 22 23 24 25 Generator Power Panel 495 290 Europe Generator Power Panel 495 288 S America 29 30 31 32 Generator Power Panel 495 283 S E Asia Generator Power Panel 495 298 USA 26 27 28 18 19 21 20 35 36 37 34 4 5 3 6 1 2 9 11 Figure 16 2 Generato...

Page 78: ...90 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 15...

Page 79: ...Notes ...

Page 80: ...is Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 ...

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