TRAILBLAZER302 (LE246322)

Trailblazer 302Trailblazer 275 DC

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Visit our website at

www.MillerWelds.com

Processes

TM-4426N 2012−04

Eff. w/Serial Number LE246322

Description

Engine Driven Welding Generator(AC Available On AC/DC Modles Only)

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW)

Air Plasma Cutting and Gougingwith Spectrum� Unit

Air Carbon Arc (CAC-A) Cuttingand Gouging

File: Engine Drive

TM-4426Trailblazer 302, 275 DC

INFORMATION ON OLDER UNITS� This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable

Owner’s Manual from www.MillerWelds.com

� Eff w/Serial No. LG074229, the Kohler-powered unit began using a 23 HP engine (replacing the 20 HP engine).

� Lift Arc w/Auto Crater was not available prior to LG074049.

� Effective with Serial Number LH140406Q, capacitors C39 and C41 are incorporated onto Power Board PC1 and PC1 is also used for power regula-tion.

� Dry charge batteries are no longer provided. Information on activating a dry battery can be obtained by downloading the applicable Owner’s Manualfrom www.MillerWelds.com.

� On early units, peak generator power output at the receptacles was 10.5 kVA/kW. Peak generator power output is now 11 kVA/kW.

� Eff w/Serial No. LK490001H, a Kohler ECH730 EFI engine was made available.

� The fuel system became EPA Evaporative Standard compliant in March 2012. See Parts list for serial number listing.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. EMF Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 2 − DEFINITIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbol Definitions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − SPECIFICATIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Weld, Power, And Carbureted Engine Specifications (Subaru EH65, Kohler CH-23) 5. . . . . . . . . . . . .

3-2. Weld, Power, And EFI Engine Specifications (Kohler ECH-730) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Dimensions, Weights, And Operating Angles 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Fuel Consumption Curves 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Generator Power Curve 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Duty Cycle 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Stick And MIG Mode Volt-Ampere Curves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. TIG Mode Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 4 − INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Serial Number And Rating Label Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Welding Generator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Grounding Generator To Truck Or Trailer Frame 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Installing Exhaust Pipe 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Engine Prestart Checks (Kohler-Powered Units) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Engine Prestart Checks (Subaru-Powered Units) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Connecting Or Replacing The Battery 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Electronic Fuel Injection (EFI) System And Battery Information 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Weld Output Terminals 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Connecting To Weld Output Terminals 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Selecting Weld Cable Sizes* 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Remote Receptacle Information 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING WELDING GENERATOR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Front Panel Controls (See Section 5-2) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Front Panel Controls (See Section 5-1) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Cold Weather Engine Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Process/Contactor Switch On AC/DC Models 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Stick Start Procedure − Scratch Start Technique 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Lift-Arc� TIG With Auto-Crater� And Auto-Stop� 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Remote Voltage/Amperage Control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 − OPERATING AUXILIARY EQUIPMENT 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Generator Power Receptacles And Supplementary Protectors 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Optional GFCI Receptacles 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Simultaneous Weld And Power 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 27. . . . . . . . . . . . . . . . . .SECTION 7 − MAINTENANCE & TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Maintenance Label 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Routine Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Electronic Fuel Injection (EFI) System And Servicing Information 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Servicing Optional Spark Arrestor 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Servicing Air Cleaner 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) 31. . . . . . . . . . . . . . . . . . . . . . . .

7-7. Changing Engine Oil, Oil Filter, and Fuel Filter (Subaru-Powered Units) 32. . . . . . . . . . . . . . . . . . . . . . .

7-8. Adjusting Engine Speed (Kohler Carbureted Units [CH-23]) 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

7-9. Adjusting Engine Speed (Kohler EFI Units [ECH-730]) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10. Adjusting Engine Speed (Subaru-Powered Units) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11. Overload Protection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − THEORY OF OPERATION 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 − TROUBLESHOOTING 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Troubleshooting Tables 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Troubleshooting Flow Charts 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3. Troubleshooting Circuit Diagram For Welding Generator (AC/DC Models) (Use With Section 9-4) 50. . .9-4. Troubleshooting Values For Circuit Diagram (AC/DC Models) (Use With Section 9-3) 52. . . . . . . . . . . . .9-5. Waveforms For Section 9-3 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Power Board PC1 Testing Information Prior To LH140406Q 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7. Power Board PC1 Test Point Values Prior to LH140406Q 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. Power Board PC1 Testing Information Eff w/LH140406Q 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. Power Board PC1 Test Point Values Eff w/LH140406Q 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10. Control Board PC2 Testing Information Prior To LJ390195Q 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Control Board PC2 Test Point Values Prior To LJ390195Q 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12. Control Board PC2 Testing Information Eff w/LJ390195Q 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Control Board PC2 Test Point Values Eff w/LJ390195Q 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14. Replacing Brushes And Cleaning Slip Rings 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-15. Adjusting Wire (MIG) Weld Puddle Consistency (Units With Stabilizer Tabs) 69. . . . . . . . . . . . . . . . . . . .9-16. Troubleshooting Kohler EFI Engine (ECH−730) Using Malfunction Indicator Light 70. . . . . . . . . . . . . . .9-17. Checking Unit Output After Servicing 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − DISASSEMBLY AND REASSEMBLY 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Disassembly/Reassembly Of Unit 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Disassembly/Reassembly Of Generator 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3. Other Torque Values 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4. Replacing Gas Tank 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 − PARTS LIST EFF W/LE246322 AND FOLLOWING 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-4426 Page 1Trailblazer 302, 275 DC

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICINGProtect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol UsageOM-4426AD - 2012−03, safety_rtm 2011-10

DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE − Indicates statements not related to personal injury.

� Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard.

Only qualified persons should test, maintain, and repair thisunit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Stop engine and remove input power plug from

receptacle (if applicable) before testing or re-pairing unit unless the procedure specificallyrequires an energized unit.

� Insulate yourself from ground by standing or working on dry insu-lating mats big enough to prevent contact with the ground.

� Do not leave live unit unattended.� If this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.� When testing live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

SIGNIFICANT DC VOLTAGE exists in inverter powersources AFTER stopping engine.� Stop engine on inverter and discharge input capacitors according

to instructions in Troubleshooting Section before touching anyparts.

MOVING PARTS can injure.

� Keep away from moving parts such as fans,belts, and rotors.

� Keep away from pinch points such as driverolls.

� Have only qualified people remove doors,panels, covers, or guards for maintenanceand troubleshooting as necessary.

� Keep hands, hair, loose clothing, and toolsaway from moving parts.

� Before working on generator, remove spark plugs or injectorsto keep engine from kicking back or starting.

� Block flywheel so that it will not turn while working on genera-tor components.

� Reinstall doors, panels, covers, or guards when servicing isfinished and before starting engine.

FLYING METAL or DIRT can injure eyes.

� Wear safety glasses with side shields or faceshield during servicing.

� Be careful not to short metal tools, parts, orwires together during testing and servicing.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

� Use proper static-proof bags and boxes tostore, move, or ship PC boards.

Using a generator indoors CAN KILLYOU IN MINUTES.

� Generator exhaust contains carbon monoxide.This is a poison you cannot see or smell.

� NEVER use inside a home or garage, EVEN IFdoors and windows are open.

� Only use OUTSIDE and far away from windows, doors, andvents.

FUEL can cause fire or explosion.

� Stop engine and let it cool off before checking oradding fuel.

� Do not add fuel while smoking or if unit is nearany sparks or open flames.

� Do not overfill tank; clean up any spilled fuel.

FIRE OR EXPLOSION hazard.� Do not place unit on, over, or near combustible surfaces.

� Do not service unit near flammables.

BATTERY EXPLOSION can BLIND.

� Always wear a face shield, rubber gloves, andprotective clothing when working on a battery.

� Stop engine before disconnecting or connect-ing battery cables.

� 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.� Disconnect negative (−) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

� Do not tip battery.� Replace damaged battery.� Flush eyes and skin immediately with water.

TM-4426 Page 2 Trailblazer 302, 275 DC

STEAM AND HOT COOLANT can burn.

� If possible, check coolant level when engine iscold to avoid scalding.

� Always check coolant level at overflow tank, ifpresent on unit, instead of radiator.

� If the engine is warm, checking is needed, and there is no over-flow tank, follow the next two statements.

� Wear safety glasses and gloves and put a rag over radiator cap.� Turn cap slightly and let pressure escape slowly before

completely removing cap.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.

� Wearers of Pacemakers and other ImplantedMedical Devices should keep away from serv-icing areas until consulting their doctor and thedevice manufacturer.

FALLING EQUIPMENT can injure.

� Use lifting eye to lift unit and properly installedaccessories only, NOT gas cylinders. Do notexceed maximum lift eye weight rating (seeSpecifications).

� Use equipment of adequate capacity to lift andsupport unit.

� If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

� Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94−110) when manu-ally lifting heavy parts or equipment.

HOT PARTS can burn.

� Do not touch hot engine parts bare-handed.� Allow cooling period before working on

equipment.� To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

TILTING OR TIPPING can injure.

� Do not put any body part under unit while lifting.� Always use proper equipment (hoists, slings,

chains, blocks, etc.) of adequate capacity to liftand support components (stator, rotor, engine,etc.) as needed during job.

PINCH POINTS can injure.� Be careful when working on stator and rotor assemblies.

EXPLODING PARTS can injure.

� Failed parts can explode or cause other parts toexplode when power is applied to inverters.

� Always wear a face shield and long sleeveswhen servicing inverters.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

� Have only qualified persons familiar with elec-tronic equipment perform this installation.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

� If notified by the FCC about interference, stop using the equip-ment at once.

� 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 tominimize the possibility of interference.

OVERUSE can cause OVERHEATING.

� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before

starting to weld again.� Do not block or filter airflow to unit.

SHOCK HAZARD from testing.

� Stop engine or turn Off welding power source (ifapplicable) before making or changing meterlead connections.

� Use at least one meter lead that has a self-retaining spring clip such as an alligator clip.

� Read instructions for test equipment.

READ INSTRUCTIONS.

� Use Testing Booklet (Part No. 150 853) whenservicing this unit.

� Consult the Owner’s Manual for welding safetyprecautions.

� Use only genuine replacement parts from the manufacturer.� Read and follow all labels and the Technical Manual carefully be-

fore installing, operating, or servicing unit. Read the safety in-formation at the beginning of the manual and in each section.

� Reinstall injectors and bleed air from fuel system according toengine manual.

HYDRAULIC EQUIPMENT can injureor kill.� Before working on hydraulic system, turn off

and lockout/tagout unit, release pressure, andbe sure hydraulic pressure cannot be accident-ally applied.

� Do not work on hydraulic system with unit running unless you are aqualified person and following the manufacturer’s instructions.

� Do not modify or alter hydraulic pump or manufacturer-suppliedequipment. Do not disconnect, disable, or override any safetyequipment in the hydraulic system.

� Keep away from potential pinch points or crush points created byequipment connected to the hydraulic system.

� Do not work under or around any equipment that is supported onlyby hydraulic pressure. Properly support equipment by mechanicalmeans.


HYDRAULIC FLUID can injure or kill.

� Before working on hydraulic system, turn off andlockout/tagout unit, release pressure, and be surehydraulic pressure cannot be accidentally applied.

� Relieve pressure before disconnecting or con-necting hydraulic lines.

� Check hydraulic system components and all con-nections and hoses for damage, leaks, and wearbefore operating unit.

� Wear protective equipment such as safetyglasses, leather gloves, heavy shirt and trousers,high shoes, and a cap when working on hydraulicsystem.

� Use a piece of paper or cardboard to search for leaks−−never usebare hands. Do not use equipment if leaks are found.

� HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulicsnear sparks or flames; do not smoke near hydraulic fluid.

� Reinstall doors, panels, covers, or guards when servicing isfinished and before starting unit.

� If ANY fluid is injected into the skin, it must be surgically removedwithin a few hours by a doctor familiar with this type of injury or gan-grene may result.

COMPRESSED AIR EQUIPMENT caninjure or kill.

� Before working on compressed air system, turnoff and lockout/tagout unit, release pressure,and be sure air pressure cannot be accidentallyapplied.

� Do not work on compressed air system with unit running unlessyou are a qualified person and following the manufacturer’s in-structions.

� Do not modify or alter compressor or manufacturer-suppliedequipment. Do not disconnect, disable, or override any safetyequipment in the compressed air system.

� Keep away from potential pinch points or crush points created byequipment connected to the compressed air system.

� Do not work under or around any equipment that is supported onlyby air pressure. Properly support equipment by mechanicalmeans.

COMPRESSED AIR can injure or kill.

� Before working on compressed air system,turn off and lockout/tagout unit, release pres-sure, and be sure air pressure cannot be acci-dentally applied.

� Relieve pressure before disconnecting or con-necting air lines.

� Check compressed air system componentsand all connections and hoses for damage,leaks, and wear before operating unit.

� Do not direct air stream toward self or others.� Wear protective equipment such as safety glasses, hearing pro-

tection, leather gloves, heavy shirt and trousers, high shoes, anda cap when working on compressed air system.

� Use soapy water or an ultrasonic detector to search forleaks−−never use bare hands. Do not use equipment if leaks arefound.

� Reinstall doors, panels, covers, or guards when servicing isfinished and before starting unit.

� If ANY air is injected into the skin or body seek medical help im-mediately.

TRAPPED AIR PRESSURE AND WHIPPINGHOSES can injure.

� Release air pressure from tools and system be-fore servicing, adding or changing attach-ments, or opening compressor oil drain or oil fillcap.

1-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.

1-4. EMF Information

Electric current flowing through any conductor causes localized electricand magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, restrict access for passers−by or conduct individual risk as-sessment for welders. All welders should use the following proceduresin order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in thewelding circuit as possible.

5. Connect work clamp to workpiece as close to the weld aspossible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.


SECTION 2 − DEFINITIONS

2-1. Symbol Definitions

Stop EngineFast

(Run, Weld/Power)Fast/Slow(Run/Idle) Slow (Idle)

Start Engine Panel/Local Temperature Fuel

Engine Oil Engine ChokeCheck ValveClearance Battery (Engine)

EngineRead Operator’s

Manual A Amperes V Volts

MIG (GMAW),Wire Stick (SMAW) TIG (GTAW) Lift Arc TIG

Positive NegativeAlternating Current

(AC) Output

Time h Hours s SecondsProtective Earth

(Ground)

Do not switch whilewelding

RemoteReceptacle Work Connection CC Constant

Current

Wire FeedElectrodePositive Electrode Negative CV Constant

Voltage

Circuit Protector


SECTION 3 − SPECIFICATIONS

3-1. Weld, Power, And Carbureted Engine Specifications (Subaru EH65, Kohler CH-23)

WeldingMode

RatedWeldingOutput

MaximumOpen-Circuit

Voltage

Weld OutputRange

GeneratorPower Rating

Fuel Capacity Engine

CC/DC280 A, 25 V, 100%

Duty Cycle 50 20 − 300 APeak: 11 kVA/kW

(w/Weld Contactor Off)Continuous:9.5 kVA/kW,

80/40 A, 120/240 V AC,60 Hz, Single-Phase

12 gal(45 L)Tank

Subaru EH65Air-Cooled,

Two-Cylinder, Four-Cycle, 23 HP

Gasoline Engineor

Kohler CH-23Air-Cooled,

Two-Cylinder,Four-Cycle,

23 HP Gasoline Engine

CV/DC300 A, 25 V, 100%

Duty Cycle 35 13 − 35 V

CC/AC*200 A, 25 V, 60%

Duty Cycle 60 35 − 225 A

* AC/DC Models Only.

3-2. Weld, Power, And EFI Engine Specifications (Kohler ECH-730)

WeldingMode

RatedWeldingOutput

MaximumOpen-Circuit

Voltage

Weld OutputRange

GeneratorPower Rating

Fuel Capacity Engine

CC/DC280 A, 25 V, 100%

Duty Cycle 50 20 − 300 A Peak: 12 kVA/kW(w/Weld Contactor Off)

Continuous:10.5 kVA/kW,

88/44 A, 120/240 V AC,60 Hz, Single-Phase

12 gal(45 L)Tank

Kohler ECH-730Air-Cooled,

Two-Cylinder,Four-Cycle,

25 HP Electronic FuelInjected Gasoline Engine

CV/DC300 A, 25 V, 100%

Duty Cycle 35 13 − 35 V

CC/AC*200 A, 25 V, 60%

Duty Cycle 60 35 − 225 A

* AC/DC Models Only.


3-3. Dimensions, Weights, And Operating Angles

803 572 / Ref 232 769 / 240 844-A

20°

20°

20°20°

! Do not exceed tilt angles orengine could be damaged orunit could tip.

! Do not move or operate unitwhere it could tip.

Weight: 580 lb (263 kg)

Lifting Eye Weight Rating: 1280lb (580 kg)

5. 250

6. 750

32. 750

16. 500

2. 000

5. 750

1. 500 . 105

APPROXI MATELY 1” BEHI NDMOUNTI NG HOLES

LOCATE FRONT CROSS SUPPORT

LOCATE REAR CROSSSUPPORT UNDER ENGI NE

MI NI MUM GAGE − 12MI NI MUM WI DTH − 3”

Support Assembly Dimensions


3-4. Fuel Consumption Curves

On a typical job using 1/8 in. 7018electrodes (125 amps, 20% dutycycle), expect about 20 hours of op-eration with carbureted engine (24hours with EFI engine).

Welding at 150 amps at 40% dutycycle uses about 3/4 gallon of fuelper hour. Expect about 16 hours ofoperation with carbureted engine(19 hours with EFI engine).

1.00

1.25

1.50

1.75

2.00

2.25

US

GA

L./H

R.

0.00

0.25

0.50

0.75

1.00

1.50

1.75

2.25

KW AT 100% DUTY CYCLE

Idle −Kohler and Subaru

Subaru

Idle −Kohler EFI

0 2 4 6 8 10

1.00

1.25

1.50

1.75

2.00

2.25

Kohler

EFI

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

US

GA

L./H

R.

DC WELD AMPERES AT 100% DUTY CYCLE

0 35 70 105 140 175 210 245 280

Subaru

KohlerCarb.

206 135 / 206 136

Idle −Kohler and Subaru

Idle −Kohler EFI

KohlerCarb.

Kohler EFI


Ref. 220 807−B

The AC generator power curveshows the generator power avail-able in amperes at the receptacles.

Tools and motors are designed tooperate within 10% of 120/240VAC.

3-5. Generator Power Curve

0

50

100

150

200

250

300

0 10 20 30 40 50 60 70 80 90 100

AC AMPERES AT 240 V

AC

VO

LTS

+/− 10%

EFI EngineCarb Engine

0 20 40 60 80 100 120 140 160 180 200

AC AMPERES AT 120 V

0

25

50

75

100

125

150

Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating.

NOTICE − Exceeding duty cyclecan damage unit and void warranty.

� AC output is not available on allmodels.

100% Duty Cycle at 280 Amperes DC

Continuous Welding

3-6. Duty Cycle

100

150

200

250

300

350

0 10 20 30 40 50 60 70 80 90 100

AC WELD

MIG/FCAW

WE

LDIN

G A

MP

ER

ES

% DUTY CYCLE

STICK


220 310 / 220 313 / 228 631

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves ofother settings fall between thecurves shown.

A. CC/DC Stick Mode

B. CV/DC MIG Mode

3-7. Stick And MIG Mode Volt-Ampere Curves

C. CC/AC STICK Mode

� AC output is not available on all models.

40

60

80

100

120

0

20

40

60

80

100

0 100 200 300 400 500

15

20

25

30

35

40

0

5

10

15

20

25

30

35

40

100 200 300 400 500 600 7000

30

40

50

60

70

80

0

10

20

0 50 100 150 200 250 300 350

DC

VO

LTS

DC AMPERES

MIN

MAX

MIN DIG MAX DIG

DC

VO

LTS

DC AMPERES

MIN

MID

MAX

AC

VO

LTS

AC AMPERES

MIN

MAX

MIN DIG

MAX DIG


220 312−A / 220 311−A

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves ofother settings fall between thecurves shown.

� AC output is not available on allmodels.

A. CC/AC TIG Mode

B. CC/DC TIG Mode

3-8. TIG Mode Volt-Ampere Curves

20

30

40

50

10

60

50 100 150 200 25000

15

20

25

30

35

40

45

5

10

0 100 200 300 4000

MIN

MAX

AC

VO

LTS

AC AMPERES

DC

VO

LTS

DC AMPERES

MIN

MAX


SECTION 4 − INSTALLATION4-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or ratedoutput. For future reference, write serial number in space provided on back cover of this manual.

! Do not move or operate unitwhere it could tip.

! Do not lift unit from end.

! Do not weld on base. Weldingon base can cause fuel tank fireor explosion. Bolt unit downusing holes provided in base.

! Always securely fasten weld-ing generator onto transportvehicle or trailer and complywith all DOT and other applica-ble codes.

NOTICE − Do not install unit where airflow is restricted or engine may over-heat.

� See Section 3-3 for lifting eye rat-ing.

Mounting:

! Do not mount unit by support-ing the base only at the fourmounting holes. Do not useflexible mounts. Use cross-supports to adequately sup-port unit and prevent damageto base.

1 Cross-Supports

Mount unit on flat surface or usecross-supports to support base,seeSection 3-3.

install2 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712

OR

18 in.(460 mm)

18 in.(460 mm)

18 in.(460 mm)

18 in.(460 mm)

18 in.(460 mm)

OR

Movement

Location / Airflow Clearance

4-2. Installing Welding Generator

Mounting

OR

1


4-3. Grounding Generator To Truck Or Trailer Frame

! Always ground generator frame tovehicle frame to prevent electricshock and static electricity hazards.

! Also see AWS Safety & Health FactSheet No. 29, Grounding of PortableAnd Vehicle Mounted Welding Gen-erators.

! Bed liners, shipping skids, andsome running gear insulate the

welding generator from the vehicleframe. Always connect a groundwire from the generator equipmentgrounding terminal to bare metal onthe vehicle frame as shown.

! Use GFCI protection when operat-ing auxiliary equipment. If unit doesnot have GFCI receptacles, useGFCI-protected extension cord.

1 Equipment Grounding Terminal (OnFront Panel)

2 Grounding Cable (Not Supplied)3 Metal Vehicle FrameConnect cable from equipment groundterminal to metal vehicle frame. Use #8AWG or larger insulated copper wire.

� Electrically bond generator frame to ve-hicle frame by metal-to-metal contact.

rot_grnd2 2011−04 − 800 652-D

1

3

2

GND/PE

4-4. Installing Exhaust Pipe

Ref. 803 891

! Stop engine and let cool.

! Engine backfire can cause se-vere burns or other injuries.Do not point exhaust pipe to-ward control panel. Keep awayfrom exhaust outlet.

! Do not point exhaust pipe to-ward LP fuel tank (if equipped).Do not point exhaust pipe to-wards shielding gas tank (ifequipped).

! Point exhaust pipe in desireddirection but always awayfrom front panel and directionof travel.

Tools Needed:

1/2 in.


4-5. Engine Prestart Checks (Kohler-Powered Units)

Ref. 803 571−A / Ref. 803 573−A

Check all fluids daily. Engine must becold and on a level surface. Unit isshipped with 10W30 engine oil.

� Follow run-in procedure in en-gine manual.

� This unit has a low oil pressureshutdown switch. However,some conditions may cause en-gine damage before the engineshuts down. Check oil level oftenand do not use the oil pressureshutdown system to monitor oillevel.

Open top service door

FuelAdd fresh fuel before starting enginethe first time (see maintenance labelfor specifications). Stop fueling whenfuel level reaches neck tube. Do nottop off tank. Always leave filler neckempty to allow room for expansion.Check fuel level on a cold engine be-fore use each day.

To check fuel level, turn Engine Con-trol switch to Run/Idle position.LED’s indicate fuel level in tank.

Oil

� Do not exceed the ”Full” mark onthe oil level dipstick. The fuelpump may operate erratically ifcrankcase is overfilled.

After fueling, check oil with unit onlevel surface. If oil is not up to fullmark on dipstick, add oil (see mainte-nance label).

Use front panel meters to determinehours until next recommended oilchange (see Section 5-1).

� To improve cold weatherstarting:

Keep battery in good condition.Store battery in warm area.

Use correct grade oil for coldweather.

Close top service door

Full

Oil Check/Fill

Oil Fill

Full

Empty

Full

Gasoline


4-6. Engine Prestart Checks (Subaru-Powered Units)

Ref. 803 571−A / Ref. 803 572−C

Full

Check all fluids daily. Engine must becold and on a level surface. Unit isshipped with 10W30 engine oil.

� Follow run-in procedure in en-gine manual.

� This unit has a low oil pressureshutdown switch. However,some conditions may cause en-gine damage before the engineshuts down. Check oil level oftenand do not use the oil pressureshutdown system to monitor oillevel.

Open top service door.

FuelAdd fresh fuel before starting enginethe first time (see maintenance labelfor specifications). Stop fueling whenfuel level reaches neck tube. Do nottop off tank. Always leave filler neckempty to allow room for expansion.Check fuel level on a cold engine be-fore use each day.

To check fuel level, turn Engine Con-trol switch to Run/Idle position.LED’s indicate fuel level in tank.

Oil

� Do not exceed the ”Full” mark onthe oil level dipstick. The fuelpump may operate erratically ifcrankcase is overfilled.

After fueling, check oil with unit onlevel surface. If oil is not up to fullmark on dipstick, add oil (see mainte-nance label).

Use front panel meters to determinehours until next recommended oilchange (see Section 5-1).

� To improve cold weatherstarting:

Keep battery in good condition.Store battery in warm area.

Use correct grade oil for coldweather.

Close top service door.

Oil CheckOil Fill

Full

Empty

Full

Gasoline


4-7. Connecting Or Replacing The Battery

Ref. 803−573−A / Ref. 803 752-C / Ref. 202 069-A / Ref. S-0756-D

1/2 in.Tools Needed:

+ −

! Connect negative (−) batterycable last

To connect battery, open right sideengine access door.

1 Battery Holddown

To change battery, remove rear pan-el with baffle and battery holddown.

Be sure battery cables are notpinched when installing battery.

1

4-8. Electronic Fuel Injection (EFI) System And Battery InformationNOTICE − EFI system components can be damaged if these precautions are not followed:

� Do not allow the battery cables to touch opposing terminals. When connecting the battery cables attach the positive (+) cable to the positive (+)battery terminal first, followed by negative (−) cable to negative (−) battery terminal.

� Never start the engine when the cables are loose or poorly connected to the battery terminals.

� Never disconnect the battery while the engine is running.

� Never use a quick battery charger to start the engine.

� Do not charge battery with Engine Control switch On.

� Always disconnect the negative (−) battery cable before charging battery.


4-9. Weld Output Terminals

! Stop engine.

! Do not connect to CC and CVterminals at the same time.

AC/DC Models:

1 Work Weld Output Terminal

2 Stick/TIG (CC) Weld OutputTerminal

3 Wire /CV Weld Output Terminal

For MIG welding, connect work cableto Work terminal and wire feedercable to Wire (CV) terminal.

For Stick/TIG welding, connect workcable to Work terminal and electrodeholder/TIG torch cable to Stick/TIG(CC) terminal.

DC Models:

4 Negative (−) Weld OutputTerminal

5 Stick/TIG (+) Weld OutputTerminal

6 Wire (+) Weld Output Terminal

For MIG welding, connect work cableto Negative (−) terminal and wirefeeder cable to CV (Wire) terminal.

For Stick welding, connect workcable to Negative (−) terminal andelectrode holder cable to CC (Stick/TIG) terminal.

For TIG welding, connect work cableto CC (Stick/TIG) terminal and elec-trode holder cable to Negative (−)terminal.

803 571 / Ref. 287 062 / 204 353 / Ref. 287 121

321

4 5 6

Weld output terminals onunits with AC/DC output.

Weld output terminals onunits with DC output only.


4-10. Connecting To Weld Output Terminals

803 778-B

! Stop engine.

! Failure to properly connectweld cables may cause ex-cessive heat and start a fire,or damage your machine.

� Do not place anything betweenweld cable terminal and copperbar. Make sure that the sur-faces of the weld cable terminaland copper bar are clean.

1 Correct Weld CableConnection

2 Incorrect Weld CableConnection

3 Weld Output Terminal4 Supplied Weld Output

Terminal Nut

5 Weld Cable Terminal

6 Copper Bar

Remove supplied nut from weldoutput terminal. Slide weld cableterminal onto weld output terminaland secure with nut so that weldcable terminal is tight against cop-per bar.

Tools Needed:

4

2

3

1

3/4 in.

5

6

4-11. Selecting Weld Cable Sizes*NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cablesize.

! Turn off power be-fore connecting toweld output termi-nals.

! Do not use worn,damaged, under-sized, or poorlyspliced cables.

Weld OutputTerminals

Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***

100 ft (30 m) or Less 150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

WeldingAmperes

10 − 60%DutyCycle

AWG (mm2)

60 − 100%DutyCycle

AWG (mm2)

10 − 100% Duty Cycle

AWG (mm2)

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)2x2/0(2x70)

2x2/0(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2x2/0(2x70)

2x3/0(2x95)

2x3/0(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2x2/0(2x70)

2x3/0(2x95)

2x3/0(2x95)

2x4/0(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2x2/0(2x70)

2x3/0(2x95)

2x4/0(2x120)

2x4/0(2x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07


4-12. Remote Receptacle Information

� Engine runs at weld/power speed whenever a device connected to the remote receptacle is running.

803 571

A JB K I

C L N H

D M GE F

Socket* Socket Information

24 VOLTS AC

A 24 volts ac. Protected by supplementary protectorCB4.

B Contact closure to A completes 24 volt AC con-tactor control circuit and keeps engine at Runspeed in all Wire modes.

115 VOLTS ACI 115 volts ac. Protected by supplementary protec-

tor CB3.

J Contact closure to I completes 115 volts AC con-tactor control circuit.

REMOTEOUTPUT

CONTROL

C +10 volts dc output to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal fromremote control.

F Current feedback: 1 volt per 100 amperes.

H Voltage feedback: 1 volt per 10 arc volts.

GNDG Circuit common for 24 and 115 volts AC circuits.

K Chassis common.

*The remaining sockets are not used.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.


Notes


SECTION 5 − OPERATING WELDING GENERATOR5-1. Front Panel Controls (See Section 5-2)

Ref. 287 062 / Ref. 227 723-A

421 3 5

9

7

8

6


5-2. Description Of Front Panel Controls (See Section 5-1)

1 Process/Contactor Switch

See Section 5-4 for Process/Contactorswitch information.

2 Remote Receptacle

Use receptacle to connect remote control orwire feeder.

When a remote voltage/amperage control isconnected to the Remote receptacle, theAuto Sense Remote feature automaticallyswitches voltage/amperage control to the re-mote control (see Sections 4-12 and 5-7).

With remote voltage/amperage control con-nected, weld output in CC mode is deter-mined by a combination of front panel and re-mote control voltage/amperage settings. InCV mode, weld output is controlled throughremote control only.

If no remote voltage/amperage control isconnected to the Remote receptacle, thefront panel Voltage/Amperage control ad-justs voltage and amperage.

3 And 4 Displays

Displays can show weld process information(voltage and amperage) or maintenance in-formation (hourmeter, oil change count-down, or rpm).

Meter Weld Functions: In Wire modes,Voltmeter displays preset weld voltagewhen not welding. Meters display actual volt-age and amperage when welding and for fiveseconds after welding has stopped.

In Stick and TIG modes, Voltmeter readsON and Ammeter displays preset amperagewhen not welding. Meters display actual volt-age and amperage when welding and for fiveseconds after welding has stopped.

Meter Engine Maintenance Functions:See inset from maintenance label.

5 Fuel Level Indicator

With Engine running or Engine Controlswitch in Run or Run/Idle position, LED’s in-dicate fuel left in tank.

6 Voltage/Amperage Control

Use control to select weld voltage oramperage. Control may be adjusted whilewelding.

With Process/Contactor switch in any Stickor TIG setting, use control to adjust amper-age. With Process/Contactor switch in anyWire position, use control to adjust voltage.When a remote voltage/amperage control isconnected to Remote receptacle RC4, con-trol sets the maximum amperage in Stick andTIG modes, but has no effect in MIG modes.

7 Engine Control Switch

Use switch to start engine, select speed, andstop engine. In Run/Idle position, engineruns at idle speed at no load, and weld/powerspeed under load. In Run position, engineruns at weld/power speed.

Use switch in combination with meters to de-termine total engine hours and hours until

next recommended oil change (see items 3and 4 earlier in this section).

� The unit will not return to idle speedwhen the remote contactor is on andProcess/Contactor switch is in any Wireposition. The unit will return to idle speedin all other modes.

8 Engine Choke Control (CarburetedEngines Only)

Use control to change engine air-fuel mixwhen starting engine.

To Start: pull out choke (if equipped) andturn Engine Control switch to Start position.Release switch when engine starts. Slowlypush in choke (if equipped).

� If the engine does not start, let theengine come to a complete stop beforeattempting restart.

� During cold weather some gasoline en-gines encounter difficulties that are easi-ly remedied. See Section 5-3 and 9-1.

To Stop: turn Engine Control switch to Offposition.

9 DC Polarity/AC Switch (AC/DC ModelsOnly)

! Do not switch under load.

Use switch to select AC weld output or polar-ity of DC weld output.

5-3. Cold Weather Engine Operation

Ref. 216 170

1 Engine Control Switch

Carburetor Icing

Carburetor icing causes the unit to drop below the normal idle speed and thenstall. This condition occurs when the temperature is near freezing and the rela-tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu-retor. The engine typically restarts without problems but soon stalls again.

� Treat gasoline with a fuel de−icer product (isopropyl alcohol).

� Place the Engine Control switch in the Run position.

� Run engine only when expecting to frequently load it.

Breather Icing

Oil breather/pulse line icing occurs in severe cold (continuously below 0�F).Moisture accumulates in the oil from piston ring blow−by if the engine is exten-sively idled. This may cause vacuum line freezing, oil breather tube freezingor ice in the carburetor. All of these cause operating problems. Due to ice inthe lines, the engine may not restart until it is warmed to above freezing.

� Load engine and reduce idle times to prevent engine shutdowns.

� Use an electric fuel pump to avoid pulse line freezing.

� Install engine cold−weather kit.

Both Kohler (1-800-544-2444) and Subaru (1-800-277-6246) offer kits for coldweather operation. The user can install these kits. Both kits pull heated air fromthe muffler surface into the carburetor and shut the cold air off. This increasesengine temperature during operation in both idle and high speed.

� When the ambient temperatures become warmer (above 45�F) the airflow will have to be returned to normal.

1

FrequentlyLoaded

InfrequentlyLoaded


5-4. Process/Contactor Switch On AC/DC Models

1 Process/Contactor Switch

! Weld output terminals are energizedwhen Process/Contactor switch isin an Electrode Hot position and theengine is running.

� The unit will not return to idle speedwhen Process/Contactor switch is in aWire position and the remote contactoris on (closure between pins A and B onremote receptacle).

Use switch to select weld process and weldoutput on/off control (see Table 6-1 andSection 4-12).

Place switch in Remote positions to turnweld output on and off with a device con-nected to the remote receptacle.

Place switch in Electrode Hot positions forweld output to be on whenever the engineis running.

Wire Positions:

Use Wire positions for MIG welding using avoltage sensing wire feeder (Electrode Hot)or wire feeder using remote control.

Stick Positions:

Use Stick positions for stick (SMAW) andair carbon arc (CAC-A) cutting andgouging.

Stick Electrode Hot:

When switch is in a Stick Electrode Hotmode, select one of four dig settings to pro-vide additional amperage during short arclength conditions and help prevent elec-trodes from “sticking”. See Stick position

descriptions following (reading L to R):

Soft Arc (E 7018) - This setting provides alow dig/arc force setting for smooth weldperformance. A stable weld puddle withlittle arc “snap” gives excellent weld beadappearance with minimal spatter.

Medium Soft Arc - This setting provides alow to medium dig/arc force that gives aslightly more fluid weld puddle, more arc“snap”, and reduces the potential forelectrode sticking at shorter arc lengths.

Medium Stiff Arc - This setting providesmedium dig/arc force for open root verticalup joints or joints that do not requireadditional current for fit up inconsistencies.

Stiff Arc (E6010) - This setting provides ahigh dig/arc force for open root verticaldown joints where additional current isneeded to compensate for tight joint fit upwithout the need to increase overall weldingcurrent. This setting is recommended forthose who prefer a very stiff arc with 6010electrodes.

Stick Remote On/Off:

When switch is in a Stick Remote On/Offmode, select one of three settings to pro-vide additional amperage during short arclength conditions and help prevent elec-trodes from “sticking”. See Stick positiondescriptions following (reading R to L):

Soft Arc (E7018) - This setting provides alow to medium dig/arc force that gives aslightly more fluid weld puddle, more arc“snap”, and reduces the potential forelectrode sticking at shorter arc lengths.

Medium Arc - This setting provides me-dium dig/arc force for open root vertical upjoints or joints that do not require additionalcurrent for fit up inconsistencies.

Stiff Arc (E6010) - This setting provides ahigh dig/arc force for open root verticaldown joints where additional current isneeded to compensate for tight joint fit upwithout the need to increase overall weldingcurrent. This setting is recommended forthose who prefer a very stiff arc with 6010electrodes.

The dig circuit is disabled when switch is inWire or TIG positions.

TIG Positions:

TIG − Remote On/Off − Use this position forAC or DC TIG welding using remote on/offcontrol.

Electrode Hot − Lift-Arc™ w/Auto Crater™TIG (DC only) - With switch in this position,a low voltage (10 V DC) is present betweenthe electrode and workpiece preventingoverheating, sticking, or contamination ofthe electrode (see Section 5-6) as the arc isstruck.

End the arc using the Auto-Crater feature(see Section 5-6).

Electrode Hot − Lift-Arc™ w/Auto Stop™TIG (DC only) - With switch in this position,a low voltage (10 V DC) is present betweenthe electrode and workpiece preventingoverheating, sticking, or contamination ofthe electrode (see Section 5-6) as the arc isstruck.

End the arc using the Auto-Stop feature(see Section 5-6).

1

803 571−A /287 062−A


Table 6-1. Process/Contactor Switch SettingsSwitch Setting Process Output On/Off Control

Electrode Hot − Wire MIG (GMAW) Electrode Hot

Electrode Hot − StickStick (SMAW)

Select Preferred Dig Electrode Hot

Electrode Hot − StickAir Carbon Arc (CAC-A) Cutting And Gouging

Select Any Dig Electrode Hot

Electrode Hot − Lift Arc w/Auto-Crater TIG (GTAW) Lift Arc w/Auto-Crater (GTAW) (DC Only) Electrode Hot

Electrode Hot − Lift Arc w/Auto-Stop TIG (GTAW) Lift Arc w/Auto-Stop (GTAW) (DC Only) Electrode Hot

TIG − Remote On/OffTIG (GTAW) With HF Unit, Pulsing Device, Or

Remote Control (AC or DC) At Remote Receptacle

Stick − Remote On/Off Stick (SMAW) With Remote On/Off At Remote Receptacle

Wire − Wire Feeder (CV) Using Remote MIG (GMAW) At Remote Receptacle

5-5. Stick Start Procedure − Scratch Start TechniqueWith Stick selected, start arc asfollows:

1 Electrode

2 Workpiece

3 Arc

Drag electrode across workpiece likestriking a match; lift electrode slightlyafter touching work. If arc goes outelectrode was lifted to high. Ifelectrode sticks to workpiece, use aquick twist to free it.

1

2

3


5-6. Lift-Arc� TIG With Auto-Crater� And Auto-Stop�

WM Marketing

Arc Start With Lift-Arc

Arc End With Auto-Crater

Arc End With Auto-Stop

1 2

1 2

21

3

3

4

Arc Start With Lift-Arc TIG

Lift-Arc is used for the DCENGTAW process when HF Startmethod is not permitted.

Select Lift-Arc at Process/Contac-tor switch.

Turn gas on.

1 Touch or scratch.

2 Lift at any angle.

Touch tungsten electrode toworkpiece at weld start point.Slowly lift electrode. Arc is startedwhen electrode is lifted.

Maintain shielding gas coverageand eliminate tungsten and work-piece contamination by usingAuto-Crater or Auto-Stop to endthe arc.

Arc End With Auto-Crater:

� Remote control is not neededwhen using Auto-Crater.

1 While welding.

2 Lift torch slightly to startAuto-Crater end (current isreduced).

3 Lower torch. Weld currentramps down.

4 Shielding gas continues untilshut off.

Arc End With Auto-Stop:

1 While welding.

2 Lift torch to start Auto-Stop.(Lift higher than that neededto start Auto-Crater.) Arcstops.

3 Move torch back down tomaintain gas coverage andprevent contamination.

OR


5-7. Remote Voltage/Amperage Control

1 Remote Receptacle RC4

Connect optional remote voltage/amperage (V/A) control to RC4(see Section 4-12).

With remote control connected,weld output in a CC mode (Stick,TIG) is determined by a combina-tion of front panel and remote con-trol voltage/amperage settings. InCV mode (Wire), weld output iscontrolled through remote controlonly.

2 Remote Hand Control(Optional)

3 Remote Foot Control(Optional)

� Engine runs at weld/powerspeed in Wire mode whenevera device connected to the re-mote receptacle makes clo-sure between pins A and B. Inall other modes, the engineruns at idle speed until a load isapplied.

803 571−A / 216 170−A / S-0769 / S-0774

Process = Stick (Using Remote On/Off)In Example:

2

Max = 160 A CC/DCMin = 25 A CC/DC

Max (160 A DC)

Min (25 A DC)

Connect RemoteV/A Control To

RemoteReceptacle RC4

Set V/A Control(Mid-Range: About 160 A)

Adjust Remote V/A Control(Stick Welding Only)

3

1

Select Polarity ByUsing DC Polarity/ACSwitch (If Present) OrBy Changing Cable

Connections

Switchpresent onAC/DCmodelsonly.


SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. Generator Power Receptacles And Supplementary Protectors

Ref. 287 062

4

! If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord.

� Generator power decreases as weldcurrent increases.

1 240 V 50 A AC Receptacle RC1

RC1 supplies 60 Hz single-phase power atweld/power speed. Maximum output is 11kVA/kW.

2 120 V 20 A AC Duplex ReceptacleRC2

3 120 V 20 A AC Duplex ReceptacleRC3

RC2 and RC3 supply 60 Hz single-phasepower at weld/power speed. Maximum out-put from RC2 or RC3 is 2.4 kVA/kW (20 Ax 120 V).

4 Supplementary Protector CB1

CB1 protects receptacles RC1, RC2, RC3,and 115 volt AC output to Remote Recep-tacle RC4 from overload. If CB1 opens, thereceptacles do not work and 115 volt ACoutput to Remote Receptacle RC4 stops.Place switch in On position to reset.



CB2 protects RC2 from overload. CB3 pro-tects RC3 and the 115 volt AC output to Re-

mote Receptacle RC4 from overload. IfCB2 opens, RC2 does not work. If CB3opens, RC3 does not work and the 115 voltAC output to RC4 stops. Press button to re-set.

� If supplementary protector continues toopen, contact Factory Authorized Ser-vice Agent.

Combined output of all receptacles limitedto peak rating of the generator.

Example: If 20 A is drawn from each 120 Vduplex receptacle, only 25 A is available atthe 240 V receptacle:

2 x (120 V x 20 A) + (240 V x 25 A) = 11 kVA/kW

1

2

3

5 6

6-2. Optional GFCI Receptacles

! Use GFCI protection when operating auxiliaryequipment. If unit does not have GFCI recep-tacles, use GFCI-protected extension cord.

� Generator power decreases as weld current in-creases.

Combined output of all receptacles limited to 11 kVA/kW peak rating of the generator.

GFCI Receptacle Option

1 120 V 20 A AC GFCI Receptacles GFCI-2 andGFCI-3

GFCI2 and GFCI3 supply 60 Hz single-phase powerat weld/power speed. Maximum output from GFCI-2 orGFCI-3 is 2.4 kVA/kW. Circuit protection is the sameas standard receptacles.

If a ground fault is detected, the GFCI Reset buttonpops out, red light turns on, and the circuit opens to dis-connect the faulty equipment. Check for damagedtools, cords, plugs, etc. connected to the receptacle.Press button to reset receptacle and resume opera-tion.

� At least once a month, run engine at weld/powerspeed and press Test button to verify GFCI isworking properly.

! If GFCI red light blinks continuously, replacereceptacle.Ref. 287 062

1


6-3. Simultaneous Weld And Power

Weld Current in Amperes Total Power in Watts 120 V Receptacle Amperes 240 V Receptacle Amperes

300 1000 10 5

250 3500 31 15

200 5200 46 23

150 6700 60 30

100 8000 70 35

0 11,000 88 44

6-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

plug1 11/03 − 120 813-D

The plug can be wired for a 240 V,2-wire load or a 120/240V, 3-wireload. See circuit diagram.

1 Plug Wired for 120/240 V,3-Wire Load

When wired for 120 V loads, eachduplex receptacle shares a loadwith one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-WireLoad

3 Neutral (Silver) Terminal

4 Load 1 (Brass)Terminal

5 Load 2 (Brass) Terminal

6 Ground (Green) Terminal

7 Amperes Available using120/240 V Plug

1

2

3

4

56

3

4

5

6

240V

240V

120V120V

Tools Needed:

240 V AC

120 V AC 120 V AC

7

*One 240 V load or two 120 V loads.

Current Available in Amperes

240 VReceptacle*

Each 120 V DuplexReceptacle

V x A = Watts

05

10152025303540

2020202020151050


SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Maintenance Label


7-2. Routine Maintenance

� Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 5-1). The Voltmeter and Ammeter display total engineoperating hours at start-up.

� Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extendedperiod.

! Stop engine before maintaining.

� See Engine Manual and Maintenance Labelfor important start-up, service, and storageinformation. Service engine more often ifused in severe conditions.

Recycle enginefluids.

� = Check = Change = Clean � = Replace* To be done by Factory Authorized Service Agent

Reference

Every8Hours

Section 4-5,4-6, 5-2

� Fuel Level � Oil Level � Meters for next oilchange interval

Oil, Fuel Spills

Every25Hours

Section 7-4,7-5

� Spark Arrestor Screen Air Cleaner Wrapper

Every50Hours

Weld Terminals

Every100Hours

EngineManual,Section 7-5,7-6, 7-7

Battery Terminals Cooling System Oil �� Air Cleaner Element

Every200Hours

EngineManual,Section 7-6,7-7

� Unreadable Labels � Spark Plug Gap Oil Filter � Fuel Filter

Every500Hours

EngineManual

�� Weld Cables � Slip Rings*� Brushes*

�Valve Clearance*

NOTICE − This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative Standards.

7-3. Electronic Fuel Injection (EFI) System And Servicing InformationNOTICE − EFI system components can be damaged if these precautions are not followed:

� Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the Engine Control switch On.

� Never attempt to service any fuel system component while engine is running or the Engine Control switch is On.

� Clean any joint or fitting with approved cleaning solvent before opening to prevent dirt from entering the system.

� Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt can cause significant problems.

� Always depressurize the fuel system through the test valve in the fuel rail before disconnecting or servicing any fuel system components.

� Do not used compressed air if the system is open.

� Avoid direct water or spray contact with system components.


7-4. Servicing Optional Spark Arrestor

Ref. 803 572−A / Ref. 183 175−A


1 Spark Arrestor Screen

Clean and inspect screen. Replacespark arrestor if screen wires arebroken or missing.

1/4 in.

1

Tools Needed:

7-5. Servicing Air Cleaner

aircleaner3 11/04 − 802 772 / 803 070 / S-0759

! Stop engine.

NOTICE − Do not run engine with-out air cleaner or with dirty element.

1 Precleaner

Wash precleaner with soap and wa-ter solution. Allow precleaner to airdry completely.

Spread 1 tablespoon SAE 30 oilevenly into precleaner. Squeezeout excess oil.

2 Element

Replace element if damaged, dirty,or oily.

oil

1

2

1

2

Subaru−Powered Kohler−Powered


7-6. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)

246 198−A / S-0842


1 Oil Drain Valve

2 Oil Filter

Change engine oil and filter accord-ing to engine manual.

NOTICE − Close valve and valvecap before adding oil and runningengine.

Fill crankcase with new oil to fullmark on dipstick (see Section 4-5).

3 Secondary Fuel Filter (EFIModels Only)

4 Primary Fuel Filter

5 Fuel Line

Replace line if cracked or worn.Install new filter. Wipe up any spilledfuel.

Start engine, and check for fuelleaks.

! Stop engine, tighten connec-tions as necessary, and wipeup fuel.

Reset oil maintenance countdownby leaving the engine off and flip-ping Engine Control switch fromRun/Idle to Run three times.

2

3 or 4

5

Full

Tools Needed:

1

� Kohler EFI Model Shown

3

4


7-7. Changing Engine Oil, Oil Filter, and Fuel Filter (Subaru-Powered Units)

803 572 / S-0842


1 Oil Drain Valve

2 Oil Filter

Change engine oil and filter accord-ing to engine owner’s manual.

NOTICE − Close valve and valvecap before adding oil and runningengine.

Fill crankcase with new oil to fullmark on dipstick (see Section 4-6).

3 Fuel Filter

4 Fuel Line

Replace line if cracked or worn.Install new filter. Wipe up any spilledfuel.

Start engine, and check for fuelleaks.

! Stop engine, tighten connec-tions as necessary, and wipeup fuel.

Reset oil maintenance countdownby leaving the engine off and flip-ping Engine Control switch fromRun/Idle to Run three times.

Tools Needed:

2

3

4

1

Full

Oil Check

Oil Fill


7-8. Adjusting Engine Speed (Kohler Carbureted Units [CH-23])

803 573 / 801 209-C1/4, 3/8 in.

Tools Needed:

3

5

4

1

2

2200 − 2300 rpm(36.6 − 38.3 Hz)

3675 − 3750 rpm(61.3 − 62.5 Hz)

After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows:

Start engine and run until warm.Turn A/V control to 10.

Remove rear panel and air cleanerto access idle speed adjustments.Remove top cover to access weld/power speed adjustments.

Idle Speed Adjustment

Move Engine Control switch toRun/Idle position.

1 Throttle Solenoid

2 Mounting Screw

3 Idle Speed Screw

Loosen mounting screw. Adjust so-lenoid position so engine runs atidle speed. If necessary, back outidle speed screw so solenoid canbe moved to correct position. Tight-en mounting screw. Be sure sole-noid linkage works smoothly.

Turn idle speed screw for fine ad-justments.

Weld/Power Speed Adjustment

Move Engine Control switch to Runposition.

4 Weld/Power SpeedAdjustment Nut

5 Lock Nut

Loosen lock nut. Turn adjustmentnut until engine runs at weld/powerspeed. Tighten lock nut.

! Stop engine.

Reinstall air cleaner, end panel, andtop cover.


7-9. Adjusting Engine Speed (Kohler EFI Units [ECH-730])

246 197-A / 246 198-A

1/4, 3/8 in.

Tools Needed:

3

5

4

1

2

2200 − 2300 rpm(36.6 − 38.3 Hz)

3675 − 3750 rpm(61.3 − 62.5 Hz)


Start engine and run until warm.Turn A/V control to 10.

Remove rear panel and air cleanerto access idle speed adjustments.Remove top cover to access weld/power speed adjustments.



1 Throttle Solenoid

2 Mounting Screw

3 Idle Speed Screw

Loosen mounting screw. Adjust so-lenoid position so engine runs atidle speed. If necessary, back outidle speed screw so solenoid canbe moved to correct position. Tight-en mounting screw. Be sure sole-noid linkage works smoothly.

Turn idle speed screw for fineadjustments.



4 Weld/Power SpeedAdjustment Nut

5 Lock Nut

Loosen lock nut. Turn adjustmentnut until engine runs at weld/powerspeed. Tighten lock nut.

Close and secure top cover accesspanel.

! Stop engine.

Reinstall air cleaner, end panel, andtop cover.


7-10. Adjusting Engine Speed (Subaru-Powered Units)

803 572−C


Start engine and run until warm.

Open top cover access panel to ac-cess speed adjustments.



1 Throttle Solenoid

2 Mounting Screws

3 Idle Speed Screw

Loosen mounting screws. Adjustsolenoid position so engine runs atidle speed. If necessary, back outidle speed screw so solenoid canbe moved to correct position. Tight-en mounting screws. Be sure sole-noid linkage works smoothly.

Turn idle speed screw for fineadjustments.



4 Jam Nut

5 Lock Nut

6 Weld/Power SpeedAdjustment Screw

Loosen jam nut and lock nut. Turnadjustment screw until engine runsat weld/power speed. Tighten jamnut, and then tighten lock nut.

! Stop engine.

Close and secure top cover accesspanel.

8 mm

Tools Needed:

1

3

2

4

5

6

10 mm

2200 − 2300 rpm(36.6 − 38.3 Hz)

3675 − 3750 rpm(61.3 − 62.5 Hz)


! Stop engine.

Open left side door.

� When a supplementary protec-tor or fuse opens, it usually in-dicates a more serious prob-lem exists. Contact a FactoryAuthorized Service Agent.


CB4 protects the stator windingsupplying 24 volt AC output to Re-mote receptacle RC4. If CB4opens, 24 volt AC output to RC4stops.

� Supplementary protectorsCB1 and CB3 protect the statorwinding supplying 115 volt ACoutput to Remote ReceptacleRC4 (see Section 6-1).

Press button to reset.

2 Fuse F6 (See Parts List)

F6 protects the engine wiring sys-tem from overload. If F6 opens,engine will not crank.

Replace fuse if open.

Close left side door.

803 773−A / Ref. 216 170 / 161 001

7-11. Overload Protection

2

1


Notes

2298

95

MATERIAL THICKNESS GAUGE


A. Block Diagram1 Engine

Supplies force to turn revolvingfield.

2 Revolving Fields (Rotor)

Turn at 3700 rpm maximum for weldand power. The speed and excita-tion current of the field coils deter-mine voltages in stator windings.

3 Stator Windings

Supply power to exciter, generatorpower, and weld circuits.

4 Rectifiers VR2, VR3

Changes ac output of exciter statorwindings to dc to supply excitationcurrent to the exciter revolving field.

5 Fuse F2

Protects exciter excitation windingfrom overload.

6 Power Board PC1

Adjusts weld output by changingrevolving field current after compar-ing feedback to selected amperage/voltage setting of R1.

Controls engine speed. Without asignal from CT1 (fed through PC2),it lowers engine speed to idle (2200rpm). Engine throttle solenoid TS1is pull-to-idle.

7 Control Board PC2

Works with PC1 to control engineidle and weld process and weld out-put on/off control functions. TheVoltage/Amperage control and Pro-cess/Contactor switch are locatedon PC2

8 Current Transformer CT1

Senses output from either genera-tor power windings, and signalsPC1 and PC2 to increase to ormaintain weld speed (3700 rpm).

9 Remote Receptacle RC4

Connects remote amperage/volt-age and contactor control to unit.

10 Supplementary ProtectorsCB3, CB4

Protect Remote receptacle RC4from overload.

11 V/A Control

Changes output of stator weld wind-ings by adjusting field current levelin revolving field.

SECTION 8 − THEORY OF OPERATION

AC Or DC Control Circuits

Weld Current Circuit

Magnetic Coupling

Supplementary

10

ProtectorCB4

9

Engine

1

11

Main Field

2

Revolving Fields

4

RectifiersVR2, VR3Fuse F2

5

Mechanical Coupling

(Rotor)

Exciter Field

Weld Windings

Stator

Field SupplyWindings

Generator P

ower

Windings

3

V/A Control(LocatedOn PC2)

RemoteReceptacle

RC4

24 V AC

10

115 V ACSupplementaryProtector

CB3

(Located On PC1) (Located On PC1)


12 Process/Contactor Switch(Located On PC2)

Selects weld process and weld out-put on/off control (Remote or Elec-trode Hot).

13 Supplementary ProtectorsCB1, CB2, And CB3

Protect 120 V AC and 240 V AC re-ceptacles RC1, RC2, and RC3from overload.

14 120 V And 240 V AC Recep-tacles RC1, RC2, And RC3

Provide connection points andpower for auxiliary equipment.

15 HF Filter

Protects unit from high frequency.

16 DC Polarity/AC Switch S1(AC/DC Models Only)

Selects type and polarity of weldoutput.

17 Main Rectifier SR1

Changes ac input from weldwindings to dc with S1 in dcposition.

18 Current Transducer LEM

Provides current feedback signal toPC2.

19 Stabilizer DC-Z

Smooths out current to weld outputterminals.

20 HF Filter

Protects unit from high frequency.

21 CC, CV, And Work WeldOutput Terminals

Provide ac or dc weld output.16

MainRectifier

SR1

Work WeldOutput

Terminal

CC WeldOutput

Terminal

CV WeldOutput

Terminal

Electrode Work

17

19

2121 21

StabilizerDC-Z

DC PolarityAnd AC Switch

AC DC

6

Current

8

TransformerCT1

Supplementary

13

ProtectorCB1

Supplementary

13

ProtectorCB2, CB3

240 V AC

14

120 V AC

14

ReceptacleRC1

ReceptaclesRC2, RC3

HF Filter15

BoardPC3

HF Filter20

BoardPC5

DC

DC

18

S1

PowerBoardPC1

ControlBoardPC2

CurrentTransducer

LEM

7

12

Process/ContactorSwitch

(Located On PC2)

Voltage Feedback

Current Feedback

Prior toLF134660 Prior to

LF134660

Capacitors C48,C49 Effw/LF134660

Capacitors C45,C46 Effw/LF134660


B. Engine/Generator Training Circuit

� This circuit is for training purposesonly. It has been modified for that useand may not reflect the actual circuitfor your unit.

� Reference:DC common - lead 42Unless otherwise noted


218 722


SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting Tables

� See Sections 9-3 and 9-4 for testpoints and values.See Section 12 and following for partslocation.

� Use Miller Testing Booklet (Part No.150 853) when servicing this unit.

� See the Miller Extranet for servicememos that may aid in the repair of thisproduct.

A. Welding Trouble

Trouble Remedy

No weld output; generator power outputokay at AC receptacles.

Check weld connections.

Check control settings.

Place Process/Contactor switch in Electrode Hot position, or move switch to Remote position andconnect remote control to Remote receptacle RC4 (see Sections 4-12 and 5-1).

Clean slip rings, and install new brushes if necessary (see Section 9-14).

Disconnect leads 132 and 133 from brushes, and check continuity across slip rings. Replace rotor ifnecessary.

Check main rectifier SR1, and replace if necessary.

Check current transducer LEM, and replace if necessary.

Disconnect stator weld excitation leads 101 and 102, and check continuity between leads. Replace statorif necessary.

Check for open or shorted winding in weld stator, and replace if necessary.

Check stabilizer DC-Z for signs of winding failure. Check continuity across windings, and check for properconnections. Replace DC-Z if necessary.

Check power board PC1 and connections, and replace if necessary (see Section 9-6).

Check control board PC2 and connections, and replace if necessary (see Section 9-10).

No weld output, or generator power output at AC receptacles.

Disconnect equipment from generator power receptacles during start-up.

Check fuse F6, and replace if necessary (see Section 7-11).



Remove leads from brushholder and check resistance from each brushholder terminal to rotor shaft.All readings should be in the megaohm range or higher. Replace rotor if necessary.

Disconnect field excitation leads 103 and 104, and check continuity between leads. Replace stator ifnecessary.



Low weld output. Check control settings.

Increase V/A control setting.

Check weld connections.

Clean air cleaner.

Check engine speed, and adjust if necessary (see Section 7-8, 7-9, or 7-10).


Disconnect stator leads 103 and 104, and check for continuity between leads. Replace stator if neces-sary.


Trouble Remedy

Low weld output (Continued). Disconnect leads 132 and 133 from brushes, and check continuity across slip rings. Replace rotor ifnecessary.



Check remote receptacle RC4 for continuity and proper connections;, and replace RC4 if necessary (seeSection 4-12).



High weld output. Decrease V/A control setting.

Check engine speed, and adjust if necessary (see Section 7-8, 7-9 or 7-10).

Check for obstructed movement of throttle solenoid TS1 linkage (see Section 7-8, 7-9, or 7-10).




Erratic weld output. Check control settings.

Be sure electrode is dry and proper type for SMAW and GTAW.

Tighten and/or clean connections to electrode and workpiece.

Use correct wire and gas.

Check internal and external connections to weld output terminals.

Check leads and connections at DC Polarity/AC switch S1 (AC/DC models only).

Remove excessive coils from weld cables.



Check stabilizer DC-Z for signs of failure. Check continuity across windings, and check for properconnections. Replace DC-Z if necessary.



Weld output cannot be adjusted. Check position of Process/Contactor switch.



No remote fine amperage control. Place Process/Contactor switch in correct position (see Section 5-1).

Check and tighten connections to remote receptacle RC4 (see Section 4-12).

Remote contactor control does notactivate contactor.

Place Process/Contactor switch in Remote position.

Reset circuit breaker(s) CB3/CB4 (see Section 6-1, 6-2, or 7-11).

Check and tighten connections to remote receptacle RC4 (see Section 4-12).


No 24 volt AC power output at RemoteReceptacle RC4.

Reset circuit breaker CB4 (see Section 7-11).

Check internal and external connections to Remote receptacle RC4 (see Section 4-12).

Disconnect stator leads 111 and 88, and check for continuity between leads. Replace stator if necessary.

Lack of high frequency; difficulty in es-tablishing GTAW arc.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coilsfrom weld cables, use shorter weld cables, etc.).

Use proper size tungsten for welding amperage.


Trouble Remedy

Lack of high frequency; difficulty in es-tablishing GTAW arc (Continued).

Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connection. Repair or replace necessary parts.

Wandering arc − poor control of arcdirection.

Use proper size tungsten.

Properly prepare tungsten.

Reduce gas flow rate.

Tungsten electrode oxidizing and not re-maining bright after conclusion of weld.

Check and tighten all gas fittings.

Increase postflow time.

Shield weld zone from drafts.

Use clean filler rod or material.

Replace torch parts if water has leaked into torch.

B. Generator Power Trouble

Trouble Remedy

No generator power output at AC recept-acles; weld output okay.

Reset circuit breakers (see Section 6-1, or 6-2).


Disconnect stator leads 80 and 81, and leads 82 and 90 and check for continuity between leads. Replacestator if necessary.

No generator power output at AC recept-acles, or weld output.

Disconnect equipment from generator power receptacles during start-up.



Remove leads from brushholder and check resistance from each brushholder terminal to rotor shaft.All readings should be in the megaohm range or higher. Replace rotor if necessary.

Disconnect field excitation leads 103 and 104, and check continuity between leads. Replace stator ifnecessary.



Low generator power output at AC re-ceptacles.

Check air cleaner and foam pre-cleaner; clean or replace as necessary.


Clean and adjust spark plugs and carburetor according to engine manual.


High generator power output at AC receptacles.


Erratic generator power output at AC receptacles.

Check fuel level.

Check receptacle RC1, RC2, and RC3 wiring and connections.


Check governor according to engine manual.

Tune engine according to engine manual.


Trouble Remedy

No 115 volt AC power output at RemoteReceptacle RC4.

Reset circuit breaker CB3 (see Section 6-1, or 6-2).

Check internal and external connections to Remote receptacle RC4 (see Section 4-12).

C. Engine Trouble

Trouble Remedy

Engine does not crank. Check fuse F6, and replace if open (see Section 7-11).

Check battery, and replace if necessary.

Check plug PLG5 and plug PLG8 connections.

Check continuity and connections of Engine Control switch S2. Repair or replace if necessary.

Check engine charging and starting systems according to engine service manual.

Engine will not start. Check fuel level.



Check continuity of Engine Control switch S2, and replace if necessary.

Check engine charging system according to engine manual.

Check fuel shutoff solenoid FS1 according to engine manual (carbureted models only).

See engine manual.

Engine starts, but stops when EngineControl switch S2 returns to Run.

Check oil level. Check Low Oil Pressure Shutdown switch S5 (see engine manual for location).


Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Sec-tion 4-5 or 4-6).


Battery discharges between uses. Turn Engine Control switch S2 to Off position when unit is not being used (see Section 5-1).

Clean battery terminals and posts with baking soda solution; rinse with clear water.

Recharge battery (approximately every three months).


Check voltage regulator according to engine manual.

Unstable or sluggish engine speeds. Check fuel level. Check fuel system components.

Check position of engine choke control.

Readjust throttle linkage if necessary (see Section 7-8, 7-9 or 7-10).

Tune engine according to engine manual.

Starter stays energized after EngineControl switch S2 is released.

Check diode D1 and replace if necessary.

Check polarity of battery connections (see Section 4-7).

Engine stops during normal operation. Check fuel level. Check fuel system components.


Check oil level. Check Low Oil Pressure Shutdown switch S5 (see engine manual for location).


Check diode D1 and replace if necessary.

Make sure installation does not restrict air flow.

Check fuel shutoff solenoid FS1 according to engine manual (carbureted models only).

Engine idles but does not reach weldspeed.

Check solenoid linkage for obstructions, and readjust throttle linkage if necessary (see Section 7-8, 7-9,or 7-10).


Trouble Remedy

Engine idles but does not reach weldspeed. (Continued)


Check current transformer CT1, and replace if necessary.

Check plug PLG5 connection.



Engine does not return to idle speed. Be sure Engine Control switch S2 is in Run/Idle position.

Remove weld/generator power loads.

Be sure remote device connected to remote receptacle RC4 is turned off.

Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will notreturn to idle speed when Process/Contactor switch is in a remote position and the remote contactor ison.

Check throttle linkage for smooth, non-binding operation.


Check current transformer CT1, and replace if necessary.

Check resistance at throttle solenoid TS1.



Engine does not remain at weld/powerspeed when power or weld load is ap-plied with Engine Control switch S2 inRun/Idle position.

Insufficient load; place Engine Control switch S2 in the Run position.

Check throttle linkage for smooth, non-binding operation.

During operation in near freezing tem-peratures, engine starts and goes toidle but stalls after a few minutes.

Treat fuel with isopropyl alcohol de-icer product.

Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri-od of time.

During operation in severe cold weath-er, engine starts and goes to idle butstalls after a few minutes.

Install engine manufacturer’s kit for cold-weather operation (carbureted models only).


9-2. Troubleshooting Flow Charts

� Resistance readings should be taken with the Engine Control switch off. Voltage readings should be taken with the engine running at weld/power

speed. Voltage readings tolerance �10%.

No weld or auxiliary power output.

Start � What is resistance (R1) across exciterrevolving field brush holder assy. with Plug25 (Power Board PC1) disconnected? Thewire numbers are 133 and 134.

� If resistance is greater than 3.2 ohms(slightly higher at higher temperatures)check rotor resistance from slip ring to slipring.

� �

If there is no voltage at the brush holderassembly (V18), check for 12 volts DC atPlug 25(Power Board PC1) pins 1 and 2.

� What is voltage across the exciter revolv-ing field wires 133 and 134 (V18). Voltageshould be a minimum of 12 volts DC.

If the resistance is greater than 3.2 ohmsthe rotor is possibly open. Inspect and/orreplace the rotor.

� �

If there is no voltage at Plug 25 (PowerBoard PC1) pins 1 and 2, verify the volt-age input to the power board at Plug 24(Power Board PC1) pins 13 and 6 (V10).

� If no voltage (V10) at Plug 24 (PowerBoard PC1) pins 13 and 6, check all con-nections to the engine/battery throughPlug 5 and out to the battery from Plug 24(Power Board PC1) pins 13 and 6. In-spect and/or repair wiring.

If the resistance on the rotor is 3.2 ohms,remove the brush assembly to verify thatthe brush holder assembly is making goodcontact with the slip ring. Inspect and/orreplace the brush holder assembly andreconnect Plug 25 (Power Board PC1).

�

If the voltage is present at Plug 24 (PowerBoard PC1) pins 13 and 6 and there is stillno auxiliary output, check for 15 volts DCat Plug 21 (Power Board PC1) pins 1 and5 (V34).

� If no voltage is present at Plug 21 (PowerBoard PC1) pins 1 and 5 (V34), inspectand/or replace power board PC1.

�

If there are 15 volts at Plug 21 pins 1 and5 there is likely a problem with VoltageFeedback (V24) (wires 30 and 37 to PC2RC12 pins 1 and 3). Also check controlboard PC2.

Weld output is high and uncontrollable.

Start � Check all voltage and current settingsbefore troubleshooting.

�

Check to see if there is Open Circuit Volt-age (V1−V4) present when the processswitch is in the Remote section.

� If there is voltage present, disconnect Plug23 pins 1 and 2 (V11). With Plug 23 dis-connected OCV (V11) remains. Inspectand/or replace power board PC1.

� �

If OCV is not present proceed with trou-bleshooting. Reconnect Plug 23 for furthertroubleshooting

Remove Plugs 25 and 26 from powerboard PC1 and verify slip ring resistanceswith respect to ground.

� �

If the continuity is good, check the voltageat Plug 12 pins 1 and 3. The voltage atControl Board PC2 should equal open cir-cuit voltage.

� OCV is very high (above 90 volts DC)check voltage feedback and the continuityof wires 30 and 37 at Plug 12 pins 1 and 3at the Control Board PC2.

If meter reads “open” (high resistance) re-place power board PC1. If PC1 is markedor discolored, also replace capacitors.

If meter does not read “open” (high resist-ance), contact Factory Service Depart-ment for assistance.

� �

Check LEM for proper voltage feedback(V23) 1 volt per 100 amps of current. Ifimproper feedback voltage, inspect and/orreplace the LEM.

If no continuity, inspect and/or repair wires30 and 37. If the voltage at Plug 12 pins 1and 3 is the same as OCV, inspect and/orreplace the control board PC2


No weld open circuit voltage but auxiliary power output is normal.

Start

� Place Process/Contactor switch in anElectrode Hot position. Voltage read-ings should be taken with the enginerunning at weld/power speed.

� What is the resistance (R2) across themain field brush holder assy. with Plug 26(Power Board PC1) disconnected? Thewire numbers are 131 and 132.

� If the rotor resistance is 30.2 ohms, re-move the brush assembly to verify that thebrushes are making good contact with theslip rings. Inspect and/or replace the brushholder assembly. Reconnect Plug 26(Power Board PC1).

If the rotor resistance is greater than 30.2ohms (slightly higher at higher tempera-tures), check the rotor resistance from slipring to slip ring. If the resistance from slipring to slip ring is greater than 30.2 ohms,the rotor is possibly open. Inspect and/orreplace the rotor.

�

Measure the DC voltage across the MainField wires 131 and 132 (V19). This volt-age should be 30 volts DC in any stickmode.

�

If (V19) main field voltage tests okay,check for voltage (V12) at Plug 21 pin 4and pin 5. This voltage should be+15 volts dc.

�

Next check for voltage (V13) at Plug 21pin 5 and 6. This voltage should be −15volts DC.

�

If V10 is there but the 15 volt supplies arenot, remove the plug from the LEM andrecheck the voltages while under a noload condition.

� If the +15 and −15 volt supplies are notpresent, check V10 at PLG24 pins 6 and13 on power board.

� If the 15 volt power supplies test okay,check the voltage signal at Plug 23 pins 1and 2 (V11). This is a pulse width modula-tion signal (PWM) between the powerboard PC1 and the control board PC2.

� � �

If no voltages, inspect and/or replace thepower board.

If the voltage supplies come up with thedisconnection of the LEM, inspect and/orreplace the LEM. If the voltages are pres-ent with all of the connections established,proceed to troubleshooting.

If no voltage (V10) at Plug 24 (PowerBoard PC1) pins 13 and 6, check all con-nections to the engine/battery throughPlug 5 and out to the battery from Plug 24(Power Board PC1) pins 13 and 6. Inspectand/or repair wiring.

View the wave forms to see if the PWMsignal is present. If no PWM signal, in-spect and/or replace the control board.

If PWM signal is present with no open cir-cuit voltage, inspect and/or replace thepower board.


Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.


9-3. Troubleshooting Circuit Diagram For Welding Generator (AC/DC Models) (Use With Section 9-4)

V25,R3

V27

V28

V10

V13

V14

V12

See Section 9-6 forPC1 data

V25,R3

V27

V28

V29,R13

V29,R13

V33

V34

V35

V32

V28

V26

V29,R14

V25,R3

V27

V28

V25,R3


251 540-A

Test Equipment Needed:

V20,

V1, V2

V3, V4E, F

See Section 9-5for waveforms

A, B, C, D, E, F, G

V17, R12

V5,R4

R11

V15,R10

V19, R2

V18,R1

V6, R5

V9, R8

V8, R7

V7, R6

V24

V21

V22

V23

R9

R15

V16,

I2I1

V11, G


9-4. Troubleshooting Values For Circuit Diagram (AC/DC Models) (Use With Section 9-3)

a) All voltage readings taken with Process/Contactor Switch in Electrode Hot Stiff (6010) Stick position(unless otherwise noted).

b) Tolerance �10% unless specified.

c) Reference − single arrow references to circuit common (lead 42), double arrow reference to points indicated.

d) When running the unit under load during troubleshooting, be sure all covers and panels are closed to provide propercooling.

Voltage Readings

V1 CC/DC OCV:

Any Stick mode: 45 volts DC (weld/power rpm), 46.5 volts DC (idle rpm)

Touch Start TIG mode: 10 volts DC (weld/power rpm), 10 volts DC (idle rpm)

V2 CC/AC OCV:

Any Stick mode: 57 volts AC (weld/power rpm), 45 volts AC (idle rpm)

Touch Start TIG mode: 0 (zero)volts AC (not active)

V3 CV/DC Min. OCV: 13 volts DC (weld/power rpm), 13 volts DC (idle rpm)

V4 CV/DC Max. OCV: 35 volts DC (weld/power rpm), 35 volts DC (idle rpm)

V5 Exciter Winding: 29 volts AC (weld/power rpm), 18 volts AC (idle rpm)

V6 Weld Exciter Winding: 186 volts AC (weld/power rpm), 115 volts AC (idle rpm)

V7 24 V AC Winding: 28.5 volts AC (weld/power rpm), 18 volts AC (idle rpm)

V8, V9 Generator Power Winding: 130 volts AC (weld/power rpm), 79 volts AC (idle rpm)

V10 Battery Input: 13.5 volts DC (idle rpm), 13.5 volts DC (weld/power rpm)

V11 Pulse Width Modulation signal; see waveform G

Electrode Hot Stick Stiff mode: +1.8 volts DC (weld/power rpm), no load

Electrode Hot Stick Stiff mode: +2.1 volts DC (weld/power rpm), 25 V, 250 A load

Electrode Hot Mig mode: +1.7 volts DC (weld/power rpm), 25 V, no load

Electrode Hot Mig mode: +2.0 volts DC (weld/power rpm), 25 V, 200A load

V12 Circuit Board Power: 15 volts DC (idle rpm), 15 volts DC (weld/power rpm)

V13 Circuit Board Power: −15 volts DC (idle rpm), −15 volts DC (weld/power rpm)

V14 Engine Speed Control: 0.5 volts DC (idle rpm), 13.5 volts DC (weld/power rpm)

V15, V16, V17 Weld Windings:

Stick mode: 35.5 volts AC (idle rpm), 34 volts AC (weld/power rpm)

MIG mode minimum: 10.5 volts AC (idle rpm), 10.5 volts AC (weld/power rpm)

MIG mode maximum: 27 volts AC (idle rpm), 27 volts AC (weld/power rpm)

Touch Start TIG mode: 12 volts AC (idle rpm), 13 volts AC (weld/power rpm)

V18 Exciter Rotor: 17 volts DC (idle rpm), 30 volts DC (weld/power rpm)

V19 Weld Rotor:

Stick mode: 52 volts DC (idle rpm), 30 volts DC (weld/power rpm)

MIG mode minimum: 14 volts DC (idle rpm), 10 volts DC (weld/power rpm)

MIG mode maximum: 37 volts DC (idle rpm), 24 volts DC (weld/power rpm)

Touch Start TIG mode: 15 volts DC (idle rpm), 13 volts DC (weld/power rpm)

V20 Current Transformer: 0 volts AC (no load), 3.6 volts AC with 100 amp weld load

V21 LEM Power: 15 volts DC (idle rpm), 15 volts DC (weld/power rpm)

V22 LEM Power: −15 volts DC (idle rpm), −15 volts DC (weld/power rpm)

V23 Current Feedback: 1 volt DC per 100 amps weld load

V24 Weld Voltage Feedback: Same as voltage across weld output terminals

V25 Throttle Solenoid: +13.5 volts DC (idle rpm), 0 volts DC (weld/power rpm)

V26 Alternator Stator Output (Robin Engine): 35 volts AC (idle rpm), 54 volts AC (weld/power rpm)

V27 Alternator Stator Output (Kohler Engine): 28 volts AC (idle rpm), 49 volts AC (weld/power rpm)


Voltage Readings (continued)

V28 Voltage Regulator Output: 13.9 volts DC (idle rpm), 13.9 volts DC (weld/power rpm)

V29 Fuel Solenoid: 13.5 volts DC (idle rpm), 13.5 volts DC (weld/power rpm)

V30 Prior to LH140406Q Weld capacitor C41: 150 volts DC (idle rpm), 250 volts DC (weld/power rpm)

V31 Prior to LH140406Q Exciter Capacitor C39: 17.5 volts DC (idle rpm), 30 volts DC (weld/power rpm)

V32 Fuel Level Sender: 5 volts DC empty tank, 0.5 volts DC full tank

V33 Battery voltage supplied to Control Board PC2 when Engine Control Switch S2 is on (engine does not have to be run-ning). Supplies the 5 volt regulator on PC2.

V34 Generator Shutoff Signal: (Originates on Control Board PC2) 0 (zero) volts DC during normal operation, 15 volts DCduring fault condition.

V35 Zero Cross Signal: (Originates on Power Board PC1) 6.8 volts DC (idle rpm), 7.4 volts DC (weld power rpm)

Remote Open−Circuit Voltage Readings (Process/Contactor switch in Remote and remote contactor closed)

V1 CC/DC OCV:

Any Stick mode: 45 volts DC (weld/power rpm), 46.5 volts DC (idle rpm)

TIG mode: 46 volts DC (weld/power rpm), 36 volts DC (idle rpm)

V2 CC/AC OCV:

Any Stick mode: 56 volts AC (weld/power rpm), 46 volts AC (idle rpm)

TIG mode: 53 volts AC (weld/power rpm), 44 volts AC (idle rpm)

V3 CV/DC Min. OCV Remote Mig: 14 volts DC (weld/power rpm), none at idle as engine goes to weld/power rpm whencontactor is closed.

V4 CV/DC Max. OCV Remote Mig: 35 to 78 volts DC (weld/power rpm) (normal to bounce between these values), none atidle as engine goes to weld/power rpm when contactor is closed.

Resistance Readings

R1 Exciter Rotor: 3.2 ohms*

R2 Weld Rotor: 30.2 ohms*

R3 Throttle Solenoid: 26 ohms (Robin Engine), 26 ohms (Kohler Engine)

R4 Exciter Winding: less than 1 ohm

R5 Weld Exciter Winding: less than 1 ohm

R6 24 Volts AC Winding: less than 1 ohm

R7, R8 Generator Power Windings: less than 1 ohm

R9 Stabilizer: less than 1 ohm

R10, R11, R12 Weld Stator Windings: less than 1 ohm

R13 Fuel Solenoid: 43 ohms (Kohler Engine)

R14 Fuel Solenoid: 37.5 ohms (Robin Engine)

R15 Current Transformer: 66 ohms

* With leads removed from the brushholder, resistance should be in the megaohm range or higher when testing from sliprings to rotor shaft.

Current Readings

I1 Exciter Rotor Stick mode:

3.9 amps (idle rpm)

7.6 amps (weld/power rpm)

7.2 amps (25 V at 200 amp)

I2 Weld Rotor Stick mode:

1.8 amps (idle rpm)

0.9 amps (weld/power rpm)

1.9 amps (25 V at 200 amp)


9-5. Waveforms For Section 9-3

2 ms 20 V

A. DC/CC Mode, DC Open-Circuit Voltage

2 ms 10 V

B. DC/CC Mode, 25 Volts DC, 200 Amperes(Resistive Load)

2 ms 20 V

C. DC/CV Mode, DC Open-Circuit Voltage,V/A Control In Max Position

2 ms 20 V

D. DC/CV Mode, 25 Volts DC, 200 Amperes(Resistive Load)

gnd

gnd gnd

� The waveforms represent the output of the welding power source.When operating properly, the power source waveforms match thoseshown here.

� Do not exceed duty cycle while running unit under load fortroubleshooting purposes. Be sure unit is clean, air flow is not blocked,and all covers and panels are in place to provide proper cooling.

gnd


G. Pulse Width Modulation Signal BetweenPower Board PC1 And Control Board PC2


2 ms 50 V

E. AC/CC Mode, AC Open-Circuit Voltage

2 ms 50 V

F. AC/CC Mode, 25 Volts AC, 200 Amperes(Resistive Load)

gnd gnd

200 �s 1 V

gnd


9-6. Power Board PC1 Testing Information Prior To LH140406QBe sure plugs are secure beforetesting. Use Section 9-7 for specificvalues during testing.

1 Power Board PC1


Ref. 803 890−A /222 510-C

1

� LED Location


9-7. Power Board PC1 Test Point Values Prior to LH140406Q

Unless otherwise noted:

a) Tolerance − �10%

b) Reference − to circuit common(chassis)

c) Readings taken at no load

Voltage Readings

Receptacle Pin Value

RC21 1 Generator shutoff, 0 (zero) volts DC during normal operation, +15 volts DC during fault. Signal origi-nates from Control Board PC2.

2 +0.5 volts DC (idle rpm), +13.5 volts DC (weld/power rpm)

3 Battery voltage when Engine Control switch S2 is on.

4 +15 volts DC

5 Circuit common

6 −15 volts DC

7 Not used

8 Not used

9 Zero cross signal originates on Power Board PC1. +6.8 volts DC (idle rpm), +7.4 volts DC (weld/pow-er rpm)

10 Not used

RC22 1 0 (zero) volts DC with respect to RC22−3

2 Not used

3 0 (zero) volts DC with respect to RC22−1

RC23 1 Pulse Width Modulation signal; see waveform G





2 Circuit common

RC24 1 Not used

2 0 (zero) volts DC (weld/power rpm), +13.5 volts DC (idle rpm)

3 Battery voltage when Engine Control switch S2 is in START or engine is running

4 Not used

5 Not used

6 Circuit common

7 thru 12 Not used

13 Battery voltage when Engine Control switch S2 is on


RC25 1 Circuit common

2 Electrode Hot Stick Stick mode (values sensitive to engine speed): +16.4 volts DC (idle rpm), +29.7volts DC (weld/power rpm)

3 Not used

4 Not used


Receptacle ValuePin

RC26 1 Not used

2 Reference for RC26−3 values

3 Electrode Hot Stick mode (all settings): +52 volts DC (idle rpm), +30 volts DC (weld/power rpm)

Electrode Hot Tig mode: +15 volts DC (idle rpm), +13 volts DC (weld/power rpm)

Electrode Hot Mig mode, weld/power rpm: +24 volts DC maximum Voltage/Amperage control setting +10 volts DC minimum Voltage/Amperage control setting

Electrode Hot Mig mode, idle rpm: +37 volts DC maximum Voltage/Amperage control setting +14 volts DC minimum Voltage/Amperage control setting

4 Electrode Hot Stick Stiff mode: +115 volts AC (idle rpm), +186 volts AC (weld/power rpm)

5 Not used


RC27 1 Electrode Hot Stick Stiff mode: +18 volts AC (idle rpm), +29 volts AC (weld/power rpm)


LED Indicators

LED Description

LED5 −15 volts DC indicator: lit when −15 volts DC power supply is present

LED6 +15 volts DC indicator: lit when +15 volts DC power supply is present

LED7 Weld generator shutoff indicator: off during normal operation, on when shutoff signal is present

LED8 Not used

LED9 +12 volts DC indicator: lit when +12 volts DC is present

LED10 Not used

LED11 Not used

LED12 +12 volts DC indicator: lit when +12 volts DC is present

LED13 Not used

LED14 Exciter voltage indicator: lit when exciter voltage is present

LED15 Not used

LED16 Weld bus voltage indicator: flashes when weld bus voltage is present

LED17 Low side IGBT gate pulse indicator: lit when low side IGBT has a gate signal present

LED18 Hi com +15 volt power supply indicator: lit when hi com +15 volt power supply is present

LED19 +D15 volt power supply indicator; lit when +D15 volt power supply is present

LED20 Idle solenoid indicator: lit when machine is at weld/power rpm, off when machine is at idle rpm

LED21 Zero cross indicator: lit when zero cross (frequency monitoring) circuit is working


9-8. Power Board PC1 Testing Information Eff w/LH140406QBe sure plugs are secure beforetesting. Use Section 9-7 for specificvalues during testing.

1 Power Board PC1

2 LED 6

3 Test Point TP1


803 986−B / 230 856-A

132


9-9. Power Board PC1 Test Point Values Eff w/LH140406Q





Voltage Readings


RC21 1 Generator shutoff, 0 (zero) volts DC during normal operation, +15 volts DC during fault. Signal origi-nates from Control Board PC2.


3 Battery voltage when Engine Control switch S2 is on.

4 +15 volts DC

5 Circuit common

6 −15 volts DC

7 Not used

8 Not used

9 Zero cross signal originates on Power Board PC1. +6.8 volts DC (idle rpm), +7.4 volts DC (weld/pow-er rpm)

10 Not used

RC22 1 0 (zero) volts DC with respect to RC22−3

2 Not used

3 0 (zero) volts DC with respect to RC22−1






2 Circuit common

RC24 1 Not used

2 0 (zero) volts DC (weld/power rpm), +13.5 volts DC (idle rpm)

3 Battery voltage when Engine Control switch S2 is in Start or engine is running

4 Not used

5 Not used

6 Circuit common

7 thru 12 Not used



RC25 1 Circuit common

2 Electrode Hot Stick Stick mode (values sensitive to engine speed): +16.4 volts DC (idle rpm), +29.7volts DC (weld/power rpm)

3 Not used

4 Not used


Receptacle ValuePin

RC26 1 Not used


3 Electrode Hot Stick mode (all settings): +52 volts DC (idle rpm), +30 volts DC (weld/power rpm)

Electrode Hot Tig mode: +15 volts DC (idle rpm), +13 volts DC (weld/power rpm)

Electrode Hot Mig mode, weld/power rpm: +24 volts DC maximum Voltage/Amperage control setting +10 volts DC minimum Voltage/Amperage control setting

Electrode Hot Mig mode, idle rpm: +37 volts DC maximum Voltage/Amperage control setting +14 volts DC minimum Voltage/Amperage control setting

4 Electrode Hot Stick Stiff mode: +115 volts AC (idle rpm), +186 volts AC (weld/power rpm)

5 Not used


RC27 1 Electrode Hot Stick Stiff mode: +18 volts AC (idle rpm), +29 volts AC (weld/power rpm)


LED Indicators

LED Description

LED6 +12 volts DC indicator, lit when +12 volts DC power supply is present

Test Point Values

TP1 Description

Pin 1 Hi Com +18 volts DC with respect to RC26 Pin 3

Pin 2 Bus voltage divided by 30 with respect to − Bus voltage

Pin 3 − Bus

Pin 4 +D 18 volts DC with respect to − Bus


9-10. Control Board PC2 Testing Information Prior To LJ390195QBe sure plugs are secure beforetesting. Use Section 9-11 forspecific values during testing.

1 Control Board PC2

2 Receptacle RC11

3 Receptacle RC12

4 Receptacle RC13

5 Receptacle RC14

6 Receptacle RC15

7 Receptacle RC16

8 Receptacle RC17


224 187-A / 804 078-A

4 3

1

2 567 8

� Typical receptacle configuration.Pin 1 is denoted by dimple.

DimplePC Board Surface

� LED Location


9-11. Control Board PC2 Test Point Values Prior To LJ390195Q





Voltage Readings


RC11 1 0 (zero) volts AC with no auxiliary power load, +3.6 volts AC with 100 watt light bulb plugged in

2 Not used

3 Reference for values at RC11−1

RC12 1 Voltage feedback: same voltages as on weld output terminals

2 Not used


4 +12 volts DC when DC Polarity/AC switch S1 is in either DC position, 0 (zero) volts DC when S1 is inAC position

5 Circuit common

RC13 1 +15 volts DC

2 Current feedback: 1 volt DC per 100 amperes weld output

3 −15 volts DC

4 Circuit common

RC14 1 Remote current feedback: 1 volt DC per 100 amperes weld output

2 Remote voltage feedback: 1 volt DC per 10 volts at weld output terminals

3 Circuit common

4 +10 volts DC

5 +13 volts DC with no remote plugged into Remote receptacle RC14, 0 (zero) to 10 volts DC minimumto maximum of remote control plugged into RC14 (for all processes)

6 Remote contactor: 0 (zero) volts AC with remote contactor open, +16 volts AC with remote contactorclosed (idle rpm), +28 volts AC with remote contactor closed (weld/power rpm)

7 Not used

8 Remote contactor: 0 (zero) volts AC with remote 115 volt contactor open, +80 volts AC with remote115 volt contactor closed (idle rpm), +130 volts AC with remote 115 volt contactor closed (weld/powerrpm)

RC15 1 +5 volts DC when fuel tank is empty, +0.5 volts DC when fuel tank is full

2 Circuit common

3 Battery voltage only when Engine Control switch S2 is in START, 0 (zero) volts in all other conditions

4 Battery voltage when Engine Control switch S2 is in RUN

5 thru 10 Not used

RC16 1 Generator shutoff (origin): 0 (zero) volts DC during normal operations, +15 volts DC during fault

2 Not used


4 Zero cross signal (originates on Power Board PC1): +6.8 volts DC (idle rpm), +7.4 volts DC (weld/power rpm)

5 +15 volts DC

6 −15 volts DC


Receptacle ValuePin

7 Circuit common


9 thru 12 Not used






2 Circuit common

LED Indicators

LED Description

LED6 +5 volt DC power supply indicator: lit when +5 volts DC power supply is present

LED7 Crank signal indicator: lit when Engine Control switch S2 is in START

LED8 Over volt indicator: lit when an over volt condition has occurred, of during normal operation

LED9 Remote contactor indicator: lit when remote contactor is off, off when a remote contactor is used and the contact is closed

LED10 Not used

LED11 Current feedback indicator: lit when current feedback is present (brighter with more feedback), off with no load. If resistorR152 is not present on the board, LED11 does not work.

LED12 Fuel Sender indicator: lit brightly when tank is empty, dims as tank is filled

LED13 Voltage feedback: lit when voltage feedback is present (brighter with more feedback)

LED14 Not used

LED15 Command indicator: off to dim when Voltage/Amperage control is at minimum, brighter as control is turned towards maxi-mum

LED16 Pulse Width Modulation indicator: lit when PWM is present

LED17 Not used

LED18 Not used


9-12. Control Board PC2 Testing Information Eff w/LJ390195QBe sure plugs are secure beforetesting. Use Section 9-13 forspecific values during testing.

1 Control Board PC2

2 Receptacle RC11

3 Receptacle RC12

4 Receptacle RC13

5 Receptacle RC14

6 Receptacle RC15

7 Receptacle RC16

8 Receptacle RC17


227 804-A / 804 078-A

4 3

1

2 567 8

� Typical receptacle configuration.Pin 1 is denoted by dimple.

DimplePC Board Surface

� LED Location


9-13. Control Board PC2 Test Point Values Eff w/LJ390195Q





Voltage Readings


RC11 1 0 (zero) volts AC with no auxiliary power load, +3.6 volts AC with 100 watt light bulb plugged in

2 Not used


RC12 1 Voltage feedback: same voltages as on weld output terminals

2 Not used


4 +12 volts DC when DC Polarity/AC switch S1 is in either DC position, 0 (zero) volts DC when S1 is inAC position

5 Circuit common

RC13 1 +15 volts DC

2 Current feedback: 1 volt DC per 100 amperes weld output

3 −15 volts DC

4 Circuit common

RC14 1 Remote current feedback: 1 volt DC per 100 amperes weld output

2 Remote voltage feedback: 1 volt DC per 10 volts at weld output terminals

3 Circuit common

4 +10 volts DC

5 0 (zero) to 10 volts DC minimum to maximum of remote control plugged into RC14 (for all processes)

6 Remote contactor: 0 (zero) volts AC with remote contactor open, +16 volts AC with remote contactorclosed (idle rpm), +28 volts AC with remote contactor closed (weld/power rpm)

7 Not used

8 Remote contactor: 0 (zero) volts AC with remote 115 volt contactor open, +80 volts AC with remote115 volt contactor closed (idle rpm), +130 volts AC with remote 115 volt contactor closed (weld/powerrpm)

RC15 1 +5 volts DC when fuel tank is empty, +0.5 volts DC when fuel tank is full

2 Circuit common

3 Battery voltage only when Engine Control switch S2 is in START, 0 (zero) volts in all other conditions

4 Battery voltage when Engine Control switch S2 is in RUN

5 thru 10 Not used

RC16 1 Generator shutoff (origin): 0 (zero) volts DC during normal operations, +15 volts DC during fault

2 Not used


4 Zero cross signal (originates on Power Board PC1): +7.9 volts DC (idle rpm), +8.4 volts DC (weld/power rpm)

5 +15 volts DC

6 −15 volts DC

7 Circuit common


Receptacle ValuePin

RC16 8 +0.5 volts DC (idle rpm), +13.5 volts DC (weld/power rpm)

9 thru 12 Not used






2 Circuit common

LED Indicators

LED Description

LED6 +12 volt DC from power board indicator: lit when 12 volts DC is present

LED19 Over volt indicator: lit when an over volt condition has occurred, of during normal operation

LED20 +15 volts DC power supply indicator: lit when +15 volts DC power supply is present

LED21 −15 volts DC power supply indicator: lit when −15 volts DC power supply is present


9-14. Replacing Brushes And Cleaning Slip Rings

Ref. 803 890−A / S-0233-A

Tools Needed:

5/32 in.


� A Kohler-powered unit isshown.

1 Endbell

2 Brush Holder Assemblies

Remove brush holder assemblies.Keep hardware for reinstallation.

Do not remove brushes from hol-der. Replace brush holder assem-bly if brushes are damaged, or at ornear minimum length.

3 Slip Rings

Inspect slip rings. Under normaluse, rings turn dark brown.

If slip rings are corroded or surfaceis uneven, insulate brush leads,start engine and clean rings with acommutator stone. Remove as littlematerial as possible.

! Stop engine.

Install brush holder assemblies andremaining generator parts (seeSection 10-2 for torque values).

Reinstall side panels and cover.

1/4 in (6.4 mm)Minimum Length

1/2 in (12.7 mm)New Length

1

ReplaceDamaged Brushes

2

3


9-15. Adjusting Wire (MIG) Weld Puddle Consistency (Units With Stabilizer Tabs)

803 574−B3/8, 7/16 in.

Tools Needed:

1

2


Stabilizer DC-Z is factory connected to suitmost Wire (MIG) welding applications.

To change Wire (MIG) weld puddle consis-tency, proceed as follows:

Remove right side panels.

1 Stabilizer DC-Z

2 Stabilizer Tabs 1, 2, and 3

Tab 3 − provides stiffest weld puddle(for aluminum and mild steel)

Tab 2 − provides wetter weld puddle(for mild steel)

Tab 1 − provides wettest weld puddle(for stainless steel)

Lead 28 is connected between the Wire/CVweld output terminal and Tab 3 at the factory.

For wetter weld puddle (for mild steel):

Remove insulated sleeving from Tab 2. Dis-connect Lead 28 from Tab 3. Connect lead28 to Tab 2, reusing hardware. Insulate Tab3 with sleeving removed from Tab 2. Securesleeving with cable ties.

For wettest weld puddle(for stainless steel):

Remove insulated sleeving from Tab 1. Dis-connect Lead 28 from Tab 3. Connect lead28 to Tab 1, reusing hardware. Insulate Tab3 with sleeving removed from Tab 1. Securesleeving with cable ties.

Reinstall side panel.


9-16. Troubleshooting Kohler EFI Engine (ECH−730) Using Malfunction Indicator Light

A. Connecting Malfunction Indicator Light To Kohler EFI Engine (ECH−730)

161−008 / 246 662-A

1 Malfunction Indicator Light(MIL)

2 Alligator Clip

3 Banana Jack

4 Resistor

5 Wiring Harness GroundConnection

6 Engine Starter

MIL can be either incandescent orLED but must draw less than 0.1amps.

If an incandescent is used, it needsto be rated at about 1.4 Watts orless, or needs to have a total resist-ance of 140 ohms or more.

If an LED is used, a 1000 ohm, ½watt resistor is connected in serieswith the alligator clip and the negat-ive terminal on the LED. Insulateconnections. The banana jack mustbe 0.156 in. diameter to mate withthe female connector in the enginewiring harness.

Connect MIL banana jack to the wir-ing harness ground connection andthe alligator clip to battery voltage,typically found at the engine starter.

1

2

5

6

1

2

3

4


B. Kohler EFI Engine (ECH−730) Fault Code Guide

Check that the battery voltage isabove 11 volts DC.

Cycle the Engine Control switchbetween Off and Run, Off and Run,and to Run. Do not start the engine.

The Malfunction Indicator Light(MIL) blinks a series of times. Thenumber of time it blinks representsa number in the blink code.

A sequence of four digits make upa fault code. There is a one secondpause between the blinks of thefault code. There is a three secondpause between separate faultcodes. After the fault code or codesblink, the end code of 61 blinks in-dicating the program end. See ex-ample.

Disconnecting the battery with theengine off will clear the fault codes.

� If a blink code is present, con-tac engine Factory AuthorizedService Agent.

1 = 1 blink ( )

2 = 2 blinks ( )

3 = 3 blinks ( )

4 = 4 blinks ( )

5 = 5 blinks ( )

6 = 6 blinks ( )

7 = 7 blinks ( )

8 = 8 blinks ( )

9 = 9 blinks ( )

0 = 10 blinks ( )

(0)One second

(1)One second

(0)One second

(7)

Three seconds

(6)One second

(1)

Fault

Code 0107

End

Code 61

Example Blink Code

Affected Component FaultCode

Problem Cause(s)

Oxygen Sensor Heater 0031 O2S heater circuit highvoltage

System voltage is too high. Faulty or loose connection. Faulty sensor.

0032 O2S heater circuit low voltage System voltage is too low. Faulty or loose connection. Faulty sensor.

Manifold Absolute Pres-sure (MAP) Sensor

0107 MAP circuit low voltage oropen

Intake manifold leak. Faulty or loose connection. Faulty sensor.

0108 MAP circuit high voltage Intake manifold leak. Faulty or loose connection. Faulty sensor.

Intake Air TemperatureSensor

0112 Intake air temperature sensorcircuit low voltage

Faulty or loose connection. Faulty sensor.

0113 Intake air temperature sensorcircuit high voltage or open

Faulty or loose connection. Faulty sensor.

Coolant/Oil Sensor 0117 Coolant/oil temperaturesensor circuit low voltage

Engine operating below normal operating temperatures. Faulty ther-mostat. Faulty or loose connection. Faulty sensor.

0118 Coolant/oil temperaturesensor circuit high voltage oropen

Engine operating above normal operating temperatures. Faulty ther-mostat. Faulty or loose connection. Faulty sensor.

Throttle Position Sensor(TPS)

0122 TPS circuit low voltage oropen

Throttle shaft or bearing worn or damaged. Faulty or loose connection.Faulty sensor.


Affected Component Cause(s)ProblemFaultCode

0123 TPS circuit high voltage Throttle shaft or bearing worn or damaged. Faulty or loose connection.Faulty sensor.

Oxygen Sensor 0131 O2S 1 circuit low voltage Faulty or loose connection. Faulty sensor.

0132 O2S 1 circuit high voltage Faulty or loose connection. Faulty sensor.

Fuel System 0171 Maximum adaptation limit ex-ceeded

Fuel inlet screen/filter plugged. Low pressure at fuel rail. TPS malfunc-tion. Faulty or loose connection. Faulty sensor.

0172 Minimum adaptation limit ex-ceeded

Fuel inlet screen/filter plugged. High pressure at fuel rail. TPS mal-function. Faulty or loose connection. Faulty sensor.

0174 Lean fuel condition Fuel inlet screen/filter plugged. Low pressure at fuel rail. TPS malfunc-tion. Faulty or loose connection. Faulty sensor.

Fuel Injector 0201 Injector 1 circuit malfunction Fuel supply to injector blocked or damaged. Faulty injector. Bad fuse.Faulty or loose connection. Faulty sensor.

0202 Injector 2 circuit malfunction Fuel supply to injector blocked or damaged. Faulty injector. Bad fuse.Faulty or loose connection. Faulty sensor.

Fuel Pump 0230 Circuit low voltage or open Bad fuse. Faulty or loose connection. Faulty sensor.

0232 Circuit high voltage Faulty or loose connection. Faulty sensor.

Crankshaft PositionSensor

0336 Crankshaft position sensornoisy signal

Air gap incorrect. Loose sensor. Faulty or loose connection. Faultysensor.

0337 Crankshaft position sensorno signal

Air gap incorrect. Loose sensor. Faulty or loose connection. Faultysensor.

Ignition Coil 0351 Cylinder 1 ignition coil mal-function

Broken wire in harness (may not be visible). Faulty or loose connec-tion. Faulty sensor.

0352 Cylinder 2 ignition coil mal-function

Broken wire in harness (may not be visible). Faulty or loose connec-tion. Faulty sensor.

System Voltage 0562 System voltage low Faulty voltage regulator. Bad fuse. Faulty or loose conncetion.

0563 System voltage high Faulty voltage regulator. Bad fuse. Faulty or loose conncetion.

End of Fault Code(s) 61 End of blink code.


C. Engine ECU Reset

Ref. 246 662-A

Any service to the ECU, TPS/Throttle body or the fuel pumpshould include ECU resest.

� System will not reset when bat-tery is disconnected.

1 Jumper Wire

Use Red wire jumper from KohlerEFI service kit or make jumper wirefrom short piece of #18 AWG wire,stripped 1/8 in. (3.2 mm) on eachend.

2 Service Port

Reset Process:

Turn Engine Control switch off.

Connect red wire jumper plug toservice port or insert wire jumperbetween port sockets 1 and 3(black and white leads to the ser-vice port).

Turn Engine Control switch on, thenoff and count 10 seconds.

Turn Engine Control switch on, thenoff and count 10 seconds a secondtime.

Remove jumper plug. ECU is reset.

TPS Learn Process:

Start engine and run at low idle. Ad-just idle speed to 1500 rpm. Allowengine to dwell at 1500 rpm forabout 3 seconds. Then adjust idlespeed to final spec speed setting.Turn Engine Control switch off andcount 10 seconds.

1

2


9-17. Checking Unit Output After Servicing

803 573−A

� Also use output waveforms tocheck unit output after servic-ing (see Section 9-5).

� A Kohler-powered unit isshown.

Check engine speeds, and adjust ifnecessary (see Section 7-8, 7-9, or7-10).

1 120 Volt AC Receptacles RC2And RC3

2 240 Volt AC Receptacle RC1

Check voltage at receptacles. Withno load applied, there should be125 − 132 volts AC present at RC2and RC3, and 228 − 264 volts pres-ent at RC1.

3 Weld Output Terminals

Check open-circuit voltagesbetween terminals according toSection 9-3 (voltages V1, V2, V3,and V4).

If correct voltages are not present,repeat troubleshooting proceduresin Section 9-1.


Complete pre-operational checksin table. Reinstall cover and sidepanels.

Tools Needed:

3/8 in.

Pre-Operational Check

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged (see Parts List).

Check Fuel and oil (see Section 4-5, or 4-6).

Check and correct any fluid leaks.

Clean weld output and battery terminals. Tighten connections.

Clean outside of entire unit.

2

3

1


Notes

SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD)

SOCKET/WRENCH SELECTION TABLE(METRIC)

Specifications Socket or Wrench Size Specifications Socket or Wrench Size

Bolt Diameter

DecimalEquivalent Bolt Nut Bolt

Diameter

U.S. Decimal

EquivalentBolt Nut

1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm






5/8 in .625 in 15/16 in 1 in 18 mm .7087 in 27 mm 27 mm

3/4 in .750 in 1-1/8 in 1-1/8 in 22 mm .8661 in 32 mm 32 mm

7/8 in .875 in 1-5/16 in 1-5/16 in 24 mm .9449 in 36 mm 36 mm

1 in 1.000 in 1-1/2 in 1-1/2 in


SECTION 10 − DISASSEMBLY AND REASSEMBLY

10-1. Disassembly/Reassembly Of Unit

Tools Needed:

2

1

3


803 890−C

! Stop engine and let cool. Dis-connect battery, negative (−)cable first.

� A Robin-powered unit is shown.

Disassembly

Use Section 9 to determine if troubleis in rotor, stator, engine or a com-bination of these components.

� To aid in reassembly, mark leadsbefore disconnecting. See leadlist summary in Section 11 forconnection information.

Disassemble in sequence shown.

Remove rear panel and battery.

Disconnect fuel line, choke cable,and base ground cable. Remove aircleaner cover, engine shroud (Rob-in) or flywheel screen (Kohler), bat-tery, and spark plugs.

Disconnect:

� leads from resistor R2

� stator leads from terminal strip1T

� engine harness at center up-right

Remove component panel from cen-ter upright (components may remainconnected).

Remove front panel and reactor/sta-bilizer mounting screws. Pull frontpanel and reactor/stabilizer forwardfar enough to remove nut securinggenerator to mounting bracket.

1 Rotor Removal Tool (Miller PartNo. 147 551)

2 Rotor Removal Spacer (MillerPart No. 177 126)

3 8 x 1.25 x 40 mm Screw

Install tool and spacer on flywheel.Loosen rotor before removing engi-ne/generator assembly. Removetool from flywheel after loosening ro-tor.

! Use hoist and lifting strap tocarefully remove engine/gen-erator assembly.

Go to Section 10-2.Remove brushassembly beforeremoving frontgenerator housing.


10-2. Disassembly/Reassembly Of Generator

Ref 803 887−B

A 40 ft lb (54 N.m)

B 25 in lb (3 N.m)

C 10 ft lb (13 N.m)

GeneratorTorques:

NOTICE − Do not damage stator or rotorwindings during this procedure.DisassemblyWith engine properly supported withblocks, remove hardware securing genera-tor components.1 O−Ring or Tolerance RingReplace if generator is disassembled.2 Endbell3 Stator Windings4 Rotor

5 Generator Fan6 Engine Adapter7 Engine Adapter Baffle8 Steel Stud9 Brush Holder AssemblyReassemblyReinstall engine and generator parts usingtorque values in tables.

Reinstall reactor/stabilizer, front panel,center upright, engine shroud or screen,and component panel.

Reconnect leads as marked. Use cable tiesto keep leads from sharp edges, and hot ormoving parts.

Reconnect fuel line, choke cable, and baseground cable Reinstall spark plugs andbattery. Reconnect battery cables, nega-tive (−) cable last.

Reinstall rear panel, cover, side panels,and exhaust pipe.

2

1

4

5

6

7

8

9

A

B

C

Apply anti-seize compound(Loctite 76732) to all con-tacting surfaces betweenrotor and engine.

3

10-3. Other Torque Values

Location Hardware Torque

Generator Mounting Bracket to Base Bottom

Stabilizer Mounting PlateScrew, .312−18 x .50 Hexwhd .66D Stl Pld Slffmg 14 ft lb (19 N.m)

Upright to Base

Generator Mounting Bracket to Base Side

Engine Mounting bracket

Screw, .312−18 x .750 Hexwhd .66D Stl Pld Slffmg Tap−R 18 ft lb (24 N.m)

Engine to Base Screw, .375−16 x 2.50 Hex Hd−Pln GR5 Pld 25 ft lb (34 N.m)

Bezel Screw, K50 x 20 Pan Hd−Phl Stl Pld PT Thread Forming 25 in lb (3 N.m)

Engine to Base & Generator to Base Nut, .375−16 .56 Hex .34H Stl Pld Sem Cone Wshr .88 25 ft lb (34 N.m)


10-4. Replacing Gas Tank

Generator Mounting Bracket Bolts

Engine Mounting Bracket Bolts

Engine Mounting Bolts

Center Upright Mounting Bolts

Ref. 803 890

Tools Needed:

3

2

4


! Disconnect battery, negative (−)cable first.

Remove top cover and side panels.

Disconnect battery. Remove rear paneland battery.

1 Center Upright2 Engine Mounting Bracket

3 Fuel Tank Cover

4 Generator Mounting Bracket Bolts

5 Fuel Tank

Mark leads and disconnect as follows:

� leads at resistor R2

� engine harness and all other leadsand plugs at the fuel tank cover (cir-

cuit breakers, fuel level sending unitleads, fuel vent solenoid, etc.)

Remove component mounting bracketfrom center upright. Remove center up-right.

! Use hoist and lifting strap to holdengine/generator assembly.

Remove engine mounting bolts. Removebolts securing engine mounting bracket.Raise engine slightly. Remove enginemounting bracket.

Remove fuel tank cover; it may be neces-sary to raise engine slightly.

Clamp fuel line and disconnect from tank.

! Clean up spilled fuel.

Loosen generator mounting bracket bolts.

Remove rear mounting bolts if unit is boltedin place on skid, trailer, or running gear.

If necessary, slightly spread base. Slidegas tank out the rear of the unit.

! Clean up spilled fuel. Clean inside ofbase. Dispose of rags in fireproofcontainer.

Before installing new tank, check fuel levelsending unit as follows: empty and upright,resistance should read approximately 245ohms while empty and upside down (simu-lating “full”) resistance should read approxi-mately 28 ohms.

Install new tank. Reassemble unit in re-verse order of disassembly. Check unit ac-cording to section 9-17 before resuminguse.

1

5

18 ft lb (24 N.m)

Torques:


Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

TM−4426 Page 81Trailblazer 302, 275 DC

SECTION 11 − ELECTRICAL DIAGRAMS

� The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuitinside machine case or contact distributor for more information.

The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Trailblazer 302 LE246322 thru LF134659 218 722−C

LF134660 thru LG094547 222 089-B

LG094548 thru LH140406Q 223 714-B

LH140406Q thru MC010154R* 232 959-D

MC010154R* and following 251 540-A See Table 11-1

Trailblazer 275 DC LE339461 thru LF134659 217 544−C

LF134660 thru LG094547 222 090-B

LG094548 thru LH140406Q 223 713-B

LH140406Q thru MC010154R* 232 960-D

MC010154R* and following 251 539-A See Table 11-2

Circuit Board PC1 LE246322 thru LH140406Q 222 511-B

LH140406Q and following 230 857-A

Circuit Board PC2 LE246322 thru LJ390194Q 224 188-B

LJ390195Q and following 227 805-B

Circuit Board PC3 LE246322 thru LF134659 148 024-A

Circuit Board PC5 LE246322 thru LF134659 148 033-A

Not published

*See Parts List for complete information on serial number change for implementation of EPA compliant parts.


Figure 11-1. Circuit Diagram For Welding Generator With AC/DC Output Eff/w LE246322 Thru LF134659


218 722−C


Figure 11-2. Circuit Diagram For Welding Generator With AC/DC Output Eff/w LF134660 Thru LG094547


222 089-B


Figure 11-3. Circuit Diagram For Welding Generator With AC/DC Output Eff w/LG094548 Thru LH140405Q


223 714-B


Figure 11-4. Circuit Diagram For Welding Generator With AC/DC Output Eff w/LH140406Qthru MC010154R*


232 959-D


Figure 11-5. Circuit Diagram For Welding Generator With AC/DC Output Eff w/MC010154R*


251 540-A


Figure 11-6. Circuit Diagram For Welding Generator With DC Output Only Eff/w LE339461 Thru LF134659


217 544-D


Figure 11-7. Circuit Diagram For Welding Generator With DC Output Only Eff/w LF134660 Thru LG094547


222 090-B


Figure 11-8. Circuit Diagram For Welding Generator With DC Output Only Eff w/LG094548 ThruLH140405Q


223 713-B


Figure 11-9. Circuit Diagram For Welding Generator With DC Output Only Eff w/LH140406Q Thru MC010154R*


232 960-D


Figure 11-10. Circuit Diagram For Welding Generator With DC Output Only Eff w/MC010154R*


251 539-A


Figure 11-11. Circuit Diagram For Power Board PC1 Eff w/LE246322Through LH140405Q (1 of 2)


222 511-B


Figure 11-12. Circuit Diagram For Power Board PC1 Eff w/LE246322 Through LH140405Q (2 of 2)222 511-B


Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART


Figure 11-13. Circuit Diagram for Control Board PC2 Eff w/LE246322 And Following (1 of 2)


224 188-B


Figure 11-14. Circuit Diagram for Control Board PC2 Eff w/LE246322 And Following (2 of 2)


224 188-B


148 024−A

Figure 11-15. Circuit Diagram For Filter HF Board PC3 Eff w/LE246322 Thru LF134659

148 033-A

Figure 11-16. Circuit Diagram For HF Filter Board PC5 Eff w/LE246322 Thru LF134659


Table 11-1. Lead List Summary For Trailblazer 302 Models Eff w/LG094548 And Following

� Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).

Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-appliedgrease had been present.

Lead Connections Lead Connections NEGA BASE TO ENGINE −28−A STAB TAP TO CV STUD−ADD DASH TO WIRE10A STATOR TO SR1 (AC) 10B S1 (4) TO SR1 (AC) 12A STATOR TO AC/DC−S1 (5) OR DC−SR1 (AC W/10)14A STATOR TO SR1 (AC) 14B S1 (6) TO SR1 (AC) 16A STATOR TO SR1 (AC) 18A S1 (10) TO SR1 (NEG) 22A S1 (8) TO SR1 (POS) 26A STAB (BEG) TO ELECT (CC) 26B S1 (3) TO ELECT (CC) 30A S1 (11) TO WORK 30D PLG12 (3) TO S1 (11) 37A STAB (END) TO S6 (9) OR SR1 (POS) 37C PLG12 (1) TO S1 (9) 40A PLG15 (4) TO PLG8 41A RC5 (1) TO PLG24 (13) 41B PLG24 (14) TO PLG8 42C RC1 (GR) TO GRD STUD 42E RC2 TO GND STUD 42F RC4 (K) TO GROUND 1T (C) 42H GRD. TO GRD. 42J RC3 TO GND STUD 42K PLG24 (6) TO COM.GRD 42Y 1T (C) TO CHASSIS GRD. 43A RC5 (3) TO PLG24 (3) 45A RC5 (5) TO SPLICE 45B PLG8 TO SPLICE 45C PLG15 (3) TO SPLICE 46A RC5 (6) TO PLG8 47A RC5 (4) TO PLG8 52A RC5 (2) TO PLG24 (2) 61A FUEL SENDER TO RC15 (1) 62A FUEL SENDER TO RC15 (2) 80A STATOR TO 1T (E) 80C RC1 (W) TO 1T (E) 81A STATOR TO 1T (F) 81B CB1 (LINE) TO 1T (F) 82A STATOR TO 1T (A) 82C CB1 (LINE) TO 1T (A) 83B CB3 TO CB1 (LOAD) 83C RC1 (X) TO CB1 (LOAD) 84B CB2 TO CB1 (LOAD) 84C RC1 (Y) TO CB1 (LOAD) 85A RC3 (Y) TO CB3 85C RC4 (I) TO CB3 86A RC2 (Y) TO CB2

88A STATOR TO CB4 90A STATOR TO 1T (B) 90B RC2 (W) TO RC3 (W) 90C RC2 (W) TO 1T (B) 101A STATOR TO RC31(1)101B PLG31 (1) TO PLG26 (4) 102A STATOR TO RC31 (2)102B PLG31 (2) TO PLG26 (6) 103A STATOR TO RC31 (3)103B PLG31 (3) TO PLG27 (1) 104A STATOR TO RC31 (4)104B PLG31 (4) TO PLG27 (2) 105A RC4 (A) TO CB4 106A RC4 (B) TO PLG14 (6) 107A RC4 (C) TO PLG14 (4) 108A RC4 (D) TO PLG14 (3) 109A RC4 (E) TO PLG14 (5) 110A RC4 (F) TO PLG14 (1) 111A STATOR TO 1T (D) 111B RC4 (G) TO 1T (D) 112A RC4 (H) TO PLG14 (2) 113A RC4 (J) TO PLG14 (8) 115A PLG21 (2) TO PLG16 (8) 116A PLG23 (2) TO PLG17 (2) 117A PLG23 (1) TO PLG17 (1) 119A PLG21 (5) TO PLG16 (7) 121A PLG21 (6) TO PLG16 (6) 123A PLG21 (4) TO PLG16 (5) 125A PLG12 (4) TO S1 (1) 126A PLG12 (5) TO S1 (2) 127A PLG21 (1) TO PLG16 (1) 128A PLG21 (3) TO PLG16 (3) 129A PLG21 (9) TO PLG16 (4) 131A MAIN FIELD COM.BRUSH TO PLG26 (3) 131A RING ASSY TO ROTOR COILS 132A MAIN FIELD FRONT BRUSH TO PLG26 (2) 132A RING ASSY TO ROTOR COILS 133A EXCITER FIELD BACK BRUSH TO PLG25 (1) 133B RING ASSY TO ROTOR COILS 134A EXCITER FIELD COM.BRUSH TO PLG25 (2)135A R1 TO PLG22 (1) 136A R1 TO PLG22 (3) 141A PLG6 (1) TO PLG13 (1) 142A PLG6 (2) TO PLG13 (2) 143A PLG6 (3) TO PLG13 (3) 144A PLG6 (4) TO PLG13 (4) JUMPA JUMPER 1T (B TO E)


Table 11-2. Lead List Summary For Trailblazer 275 Models Eff w/LG094548 And Following

� Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).

Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-appliedgrease had been present.

Lead Connections Lead Connections NEGA BASE TO ENGINE −28−A STAB TAP TO CV STUD−ADD DASH TO WIRE 10A STATOR TO SR1 (AC) 12A STATOR TO AC/DC−S1 (5) OR DC−SR1 (AC W/10)14A STATOR TO SR1 (AC) 16A STATOR TO SR1 (AC) 26A STAB (BEG) TO ELECT (CC) 30A SR1 (−) THRU LEM TO WORK STUD 30C SR1 (−) TO PLG12 (3) 37A STAB (END) TO S6 (9) OR SR1 (POS) 37B SR1 (+) TO PLG12 (1) 40A PLG15 (4) TO PLG8 41A RC5 (1) TO PLG24 (13) 41B PLG24 (14) TO PLG8 42C RC1 (GR) TO GRD STUD 42E RC2 TO GND STUD 42F RC4 (K) TO GROUND 1T (C) 42H GRD. TO GRD. 42J RC3 TO GND STUD 42K PLG24 (6) TO COM.GRD 42Y 1T (C) TO CHASSIS GRD. 43A RC5 (3) TO PLG24 (3) 45A RC5 (5) TO SPLICE 45B PLG8 TO SPLICE 45C PLG15 (3) TO SPLICE 46A RC5 (6) TO PLG8 47A RC5 (4) TO PLG8 52A RC5 (2) TO PLG24 (2) 61A FUEL SENDER TO RC15 (1) 62A FUEL SENDER TO RC15 (2) 80A STATOR TO 1T (E) 80C RC1 (W) TO 1T (E) 81A STATOR TO 1T (F) 81B CB1 (LINE) TO 1T (F) 82A STATOR TO 1T (A) 82C CB1 (LINE) TO 1T (A) 83B CB3 TO CB1 (LOAD) 83C RC1 (X) TO CB1 (LOAD) 84B CB2 TO CB1 (LOAD) 84C RC1 (Y) TO CB1 (LOAD) 85A RC3 (Y) TO CB3 85C RC4 (I) TO CB3 86A RC2 (Y) TO CB2

88A STATOR TO CB4 90A STATOR TO 1T (B) 90B RC2 (W) TO RC3 (W) 90C RC2 (W) TO 1T (B) 101A STATOR TO RC31(1)101B PLG31 (1) TO PLG26 (4) 102A STATOR TO RC31 (2)102B PLG31 (2) TO PLG26 (6) 103A STATOR TO RC31 (3) OR BOBCAT 103B PLG31 (3) TO PLG27 (1) 104A STATOR TO RC31 (4) OR BOBCAT 104B PLG31 (4) TO PLG27 (2) 105A RC4 (A) TO CB4 106A RC4 (B) TO PLG14 (6) 107A RC4 (C) TO PLG14 (4) 108A RC4 (D) TO PLG14 (3) 109A RC4 (E) TO PLG14 (5) 110A RC4 (F) TO PLG14 (1) 111A STATOR TO 1T (D) 111B RC4 (G) TO 1T (D) 112A RC4 (H) TO PLG14 (2) 113A RC4 (J) TO PLG14 (8) 115A PLG21 (2) TO PLG16 (8) 116A PLG23 (2) TO PLG17 (2) 117A PLG23 (1) TO PLG17 (1) 119A PLG21 (5) TO PLG16 (7) 121A PLG21 (6) TO PLG16 (6) 123A PLG21 (4) TO PLG16 (5) 127A PLG21 (1) TO PLG16 (1) 128A PLG21 (3) TO PLG16 (3) 129A PLG21 (9) TO PLG16 (4) 131A MAIN FIELD COM.BRUSH TO PLG26 (3) 131A RING ASSY TO ROTOR COILS 132A MAIN FIELD FRONT BRUSH TO PLG26 (2) 132A RING ASSY TO ROTOR COILS 133A EXCITER FIELD BACK BRUSH TO PLG25 (1) 133B RING ASSY TO ROTOR COILS 134A EXCITER FIELD COM.BRUSH TO PLG25 (2) 141A PLG6 (1) TO PLG13 (1) 142A PLG6 (2) TO PLG13 (2) 143A PLG6 (3) TO PLG13 (3) 144A PLG6 (4) TO PLG13 (4) JUMPA JUMPER 1T (B TO E)

Visit our website at

www.MillerWelds.com

Eff w/LE246322 And FollowingFor OM-4426 (215 348) Revision A Thru AD

Processes

TM-4426N 2012−04

Description

Engine Driven Welding Generator(AC Available On AC/DC Models Only)

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW)

Air Plasma Cutting and Gougingwith Spectrum� Unit

Air Carbon Arc (CAC-A) Cuttingand Gouging

Trailblazer 302Trailblazer 275 DC

�

�

File: Engine Drive


SECTION 12 − PARTS LIST EFF W/LE246322 AND FOLLOWING

803 889−H

� Hardware is common andnot available unless listed.

1

2

34

5

6

78 57

58 9 10

11

1716

18

1920

2122

24 Fig. 12-3

25

26 27 28

29

30

31

3233

34

35

38

36

59

39

4041

4243

44

47 Fig 12-2

48

49

2950

51

52

535455

1213

23

50

4645

37

141556

Figure 12-1. Main Assembly (Kohler Engine Shown)

Eff w/LE246322 And Following


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Main Assembly

Quantity

1 211366 Panel, Side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 250795 Label, Warning Gasoline (EPA) Bilingual 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 227726 Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . .

CSA (Bilingual) (Prior to LH140791Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 233639 Label, Warning General Precautionary. . . . . . . . . . . . . . . . . . .

CSA (Bilingual) (Eff w/LH104791Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 228432 Cover, Top Service Assy Trailblazer 275 & 302 Std 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+230532 Cover Assy, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 246139 Cover, Top Service Assy Trailblazer 275 & 302 EFI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+211367 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 211365 Panel, Side LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 217395 Bumper, Rubber Press−in 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 211370 Latch, Door (Prior to LJ050306Q) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 234008 Latch, Slide (Eff w/LJ050306Q) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 238272 Door, Access Engine Side w/Latch (Service) (Prior to LJ050306Q) 1. . . . . . . . . . . . . . . . . . . . . . . .8 237305 Door, Access Engine Side (Eff w/LJ050306Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220371 Seal, Rubber w/Adhesive .370 x .750 x 14.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 211527 Pipe, Exhaust Elbow (Prior to LJ390505H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 225759 Pipe, Exhaust Elbow (Eff w/LJ390505H0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 211369 Door Assy, Access Engine Top Std 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 246052 Door Assy, Access Engine Top EFI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211370 Latch, Door (Engine Top) (Eff w/LJ050306Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 227864 Label, Engine Maintenance Subaru & Kohler (Bilingual) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 238272 Door, Access Engine Side w/Latch (Service) (Prior to LJ050306Q) 1. . . . . . . . . . . . . . . . . . . . . . . .13 237305 Door, Access Engine Side (Eff w/LJ050306Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220371 Seal, Rubber w/Adhesive .370 x .750 x 14.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227004 Cover, PC Board Bkt (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 232077 Cover, PC Board Bracket (Eff w/LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215800 Gasket, Capacitor Support (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 232078 Gasket, Capacitor Support (Eff w/LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 PC1 213257 Circuit Card Assy, Power (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 PC1 230855 Circuit Card Assy, Power (Eff w/LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215798 Bracket, Capacitor Support (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C39 210639 Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . .C41 217632 Capacitor, Elctlt 1200 Uf 300 Vdc Can 2.00 Dia (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . .

215797 Bracket, Mtg PC Board (Prior to LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 232075 Bracket, Mtg Pc Board (Eff w/LH140406Q) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 R1 188067 Resistor, Ww Fxd 100 W 200 Ohm W/Clips (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . .19 211360 Upright, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 205734 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 CB4 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 211209 Cover, Tank Fuel (Prior to LH014498) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 231118 Cover, Tank Fuel (Eff w/LH014498) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 245520 Bushing, Snap−in Nyl 1.062 Id X 1.500 Mtg Hole (Models w/EFI Engine) 1. . . . . . . . . . . . . . . . . . .24 Figure 12-3 Generator Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 228681 Muffler, Exhaust Engine (Kohler Carburetor Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 245396 Muffler, Exhaust Engine (Kohler EFI Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 228680 Muffler, Exhaust Engine (Subaru Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 209057 Clamp, Muffler 1.625 Dia U Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 217441 Muffler Gasket, (Subaru Engine) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 189477 Muffler Gasket, (Kohler Engine) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

229125 Engine, Gas Elec Start. . . . . . . . . . . . . . . . . . . . . .28 229124 Engine, Koh Gas Elec Ch23s−ps−76628 . . . . . . . . . . . . . . . . . . . . .

(Kohler Carburetor Engine) (Prior To MB021300H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251015 Engine, Koh Gas Elec Ch680-3043 . . . . . . . . . . . . . . . . . . . . . . . .

(Kohler Carburetor Engine) (Eff w/MB021300H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 245649 Engine, Koh Gas Elec (Efi) Ps-Ech730-0012 (Kohler EFI Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . .

F6 *021718 Fuse, Mintr Gl 30, Amp 32 Volt (Prior to LK430022H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Main Assembly (Continued)

Quantity

F6 215621 Fuse, 30 Amp Ato Type (Eff w/LK430022H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VOLT REG *190249 Regulator, Voltage (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TS1 199530 Solenoid, Throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bracket, Mtg Solenoid (See Engine Parts List) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180096 Tune−up & Filter Kit Kohler 20 HP (Prior to LG074229) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .*067272 Air Filter Element 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*066698 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*215985 Filter/Clamps, Fuel 1/4 in Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*067007 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*067273 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230015 Tune−up & Filter Kit Kohler 23 HP (Eff w/LG074229) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*230016 Air Filter Element 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*066698 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*215985 Filter/Clamps, Fuel 1/4 in Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*067007 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*230017 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246115 Tune−up & Filter Kit, Kohler (ECH730) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*230016 Air Filter Element 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*066698 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*246117 Filter/Clamps, Fuel 1/4 in Line (Primary) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*246123 Filter, Fuel W/Clamps (Secondary) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*067007 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*230017 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 214530 Engine, Gas Elec Start. . . . . . . . . . . . . . . . . . .218072 Engine, Subaru Gas Elec Performer Ohv (Prior to MB100018H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .251016 Engine, Subaru Gas Elec #eh650dc2481 (Eff w/MB100018H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F6 *021718 Fuse, Mintr Gl 30, Amp 32 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*198756 Pump, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VOLT REG *198778 Regulator, Voltage (Subaru) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S5 198757 Switch, Low Oil Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190827 Boot, Solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*206473 Washer, Seal Oil Copper M14id x M19.500d 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237857 Filter, Fuel In−line .250 Subaru 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199062 Tune−up & Filter Kit (Subaru) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198755 Element, Air Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*198754 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*241408 Filter, Fuel W/Clamps 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*198777 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 167788 Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 208003 Hose, Oil W/Fittings And Valve (Kohler Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 208004 Hose, Oil W/Fittings And Valve (Subaru Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 211364 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 082319 Cable, Bat Neg 17.75 No 4 Awg W/Clamp & .343 Rng (Prior to LF209429)1. . . . . . . . . . . . . . . . . . .32 245133 Cable, Battery Negative (15 In) (Eff w/LF209429) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 173921 Cable, Bat Pos 28.00 No 4 Awg W/Clamp & .312 Rng (Prior to LF209429)1. . . . . . . . . . . . . . . . . . .33 245134 Cable, Battery Positive (25 In) (Eff w/LF209429) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 182935 Hold Down, Battery 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 167677 Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Maint Free (Prior to MB410431H)1. . . . . . . . . . . . . . . . . . .35 255574 Battery, Stor 12v Gp 58 Maint Free No Handle (Eff w/MB410431H) 1. . . . . . . . . . . . . . . . . . . . . . .36 211394 Baffle, Engine Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 216641 Seal, Engine Air Baffle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 215984 Fuel Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 227913 Label, Warning Battery Explosion Can Blind (Bilingual) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 211356 Pan, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 227912 Label, Warning Do Not Weld On Base/Fuel Level (Bilingual) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 211355 Cover, Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 DC−Z 212699 Stabilizer Assy, (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 214824 Plate, Mtg Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 211091 Bracket, Mtg Rectifier (Prior to LG094548) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 228087 Bracket, Mtg Rectifier (Eff w/LG094548 thru MA410029H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 241349 Bracket, Mtg Rectifier (Eff w/MA410030H thru MB140488H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 228087 Bracket, Mtg Rectifier (Eff w/MB140489H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Main Assembly (Continued)

Quantity

46 SR1 202222 Rectifier, Si 3ph 300 Amp 400 Piv . . . . . . . . . . . . .100% Duty Cycle (Prior to LG094548) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

46 SR1 225516 Rectifier, Si 3ph 300 Amp 400 Piv . . . . . . . . . . . . .100% Duty Cycle (Eff w/LG094548 thru MA410029H) 1. . . . . . . . . . . . . .

46 SR1 242386 Rectifier, Si 3ph 300 Amp 400 Piv . . . . . . . . . . . . .100% Duty Cycle (Eff w/MA410030H thru MB140488H) 1. . . . . . . . . . . .

46 SR1 225516 Rectifier, Si 3ph 300 Amp 400 Piv . . . . . . . . . . . . .100% Duty Cycle (Eff w/MB140489H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 Figure 12-2 Panel, Front w/Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 CT1 217844 Xfmr, Current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 211358 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 010954 Washer, Flat .406idx1.250odx.125t Stl Pld 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 214556 Mount, Vibration 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 127595 Screw, 375−16x2.50 Hex Hd−pln Gr5 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 211210 Bracket, Mtg Engine (Kohler Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 211213 Bracket, Mtg Engine (Subaru Engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 230047 Bracket, Resistor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 215873 Shroud, Air Bypass (Prior to LH014498) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 225411 Shroud, Air Bypass (Eff w/LH014498) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 233088 Label, Danger Using A Generator Indoors Can Kill . . . . . . . . . . . . . . . . . . .

You In Minutes (Unit) (Eff w/ LH 140791Q) 1. . . . . . . . . . . . . . . . . . . . . . . .PC3 148021 Circuit Card Assy, Filter HF (Prior to LF134660) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PC5 148030 Circuit Card Assy, Filter HF (Prior to LF134660) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211092 Baffle, Stab (Prior to LG094548) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .� Gas tanks are EPA compliant starting 2012 week 10 (March 5, 2012). Contact Factory Service Department

to ensure correct replacement parts are ordered.57 211398 Grommet, Plastic Neck Filler Fuel (Prior to: See below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 256466 Grommet, Plastic Neck Filler Fuel (Ext Tether) (Eff w/: See below) 1. . . . . . . . . . . . . . . . . . . . . . . .58 220711 Cap, Tank Screw−on W/Vent (Prior to: See below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 255707 Cap, Tank Screw-on W/Exterior Tether (Eff w/: See below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 249359 Tank, Fuel 11.0 Gal W/Sender (Prior to: See below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 257570 Assy, Tank 11.0 Gal W/Epa Valve (Eff W/: See below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

255490 Tank, Fuel 11.0 Gal W/Sender & Running Loss Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252645 Valve, Solenoid 2-way Normally Closed 12vdc 6.5 W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124253 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250580 Bushing, Snap-in Nyl .520 Id X .875 Mtg Hole S-b 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256019 Hose, Tank Vent 3/16 Id X 38.000 W/Clamps (Carb Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256020 Hose, Tank Vent 3/16 Id X 42.000 W/Clamps (EFI Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model and Engine Stock Number Effective Serial Number of EPA Fuel Tank Change:275 Kohler 907214 MC010154R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 Subaru 907215 MC010276R. . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Kohler 907216 MC070635R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Subaru 907217 MC011136R. . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 Kohler EFI 907451 MC011220R. . . . . . . . . . . . . . . . . . . . . . . . . .302 Kohler EFI 907452 MC080406R. . . . . . . . . . . . . . . . . . . . . . . . . .Use date of manufacture to aid in obtaining correct parts for combo stock numbers.

*Recommended Spare Parts.

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Orderlabel individually or as part of Label Kit 217221.

To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.



803 888−D


12

3

45 6

78

9

10

7

1112

1314

1516

17

18

19

20

2122

2324

25

2627

29

32

30

31

28

Figure 12-2. Panel, Front w/Components



DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 47)

Quantity

1 Nameplate (Order By Model & Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 190512 Stand−off, No 6−32 X .640 Lg .250 Hex Al Fem 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 PC2 221756 Circuit Card Assy, Control (includes) (Prior to LJ390195Q) 1. . . . . . . . . . . . . . . . . . . . . . . . .3 PC2 240605 Circuit Card Assy,Control W/Shield (includes) (Eff w.LJ390195Q) 1. . . . . . . . . . . . . . . . . . .

221479 Shield, PCB Protective Anti Static 4.813x12.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 RC4 134735 Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 S1 213440 Switch, Changeover (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 086075 Bus Bar (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 CC, CV, WORK 039046 Terminal, Pwr Output Black (AC/DC Units Only) 3. . . . . . . . . . . . . . . . . . . . . . . . . .7 POS, WORK 039046 Terminal, Pwr Output Black (DC Units Only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 LEM 168829 Transducer, Current 1000a Module Max Open Loop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 CB1 218591 Supplementary Protector, Man Reset 2p 50a 240vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB2 093996 Supplementary Pro, Man Reset 1p 20a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 CB3 093996 Supplementary Pro, Man Reset 1p 20a 250vac Fric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 RC2 , RC3 222091 Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 GFCI2, GFCI3 ♦222093 Rcpt, Str Dx Grd 2p3w 20a 125v GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 S2 217680 Switch, Ignition 4 Position W/Out Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 218606 Handle, Switch Range (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 220804 Screw, 010−32x .50 Btn Hd−soc Stl Pld Patch (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . .15 211452 Control, Push/Pull Snap−in 42.000 W/1.750 Extension (Subaru) 1. . . . . . . . . . . . . . . . . . . . . . . . . .15 221516 Control,Push/Pull Snap−in 36.000 W/1.750 Extension (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .16 207073 Lever, Ignition Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 212977 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 RC1 182954 Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 215987 Bezel Assembly (AC/DC Units) (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 217068 Bezel Assembly (DC Units) (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 216775 Cover, Output Stud Wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 213914 Cover, Output Stud Stick/Tig 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 216773 Cover, Receptacle Duplex 120v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 216774 Cover, Receptacle Full Kva 120/240v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 216772 Cover, Output Stud Work (AC/DC Units) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 216771 Cover, Output Stud Negative (DC Units) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 211405 Pin, Hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 197203 Grounding Stud Assy, Brass (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010915 Washer, Flat .257idx0.640odx.031t Brs 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163167 Washer, Lock .254idx0.489odx.062t Sst Split.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601836 Nut, 250−20 .50hex .19h Brs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 223197 Baffle, Air (Eff w/LG094548 thru MA410029H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 241348 Baffle, Air (Eff w/MA410030H thru MB140488H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 223197 Baffle, Air (Eff w/MB140489H)) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 207075 Knob, Pointer 1.625 Dia. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 C49 222064 Capacitor, Polye Met Film .1 Uf 500 Vdc 10% (Eff w/LF134660) 1. . . . . . . . . . . . . . . . . . . .31 C48 222065 Capacitor Module,Polye Met Film .1 Uf 500 Vdc 10% (Eff w/LF134660) 1. . . . . . . . . . . . . .32 207080 Knob, Pointer 1.125 Dia. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦ OptionalTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.



DescriptionPartNo.

ItemNo.

Figure 12-3. Generator (Figure 12-1 Item 24)

Quantity

1 +218739 Stator, Generator (Prior to LG094548) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 +223718 Stator, Generator (Eff w/LG094548 thru MA410029H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 +245878 Stator, Generator (Eff w/MA410030 thru MB140488H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 +223718 Stator, Generator (Eff w/MB140489H) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 227724 Label, Warning Moving Parts Can Cause Serious Etc (Bilingual) 1. . . . . . . . . . . . . . . . . . . . . . . . . .3 215346 Rotor, Generator (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 181143 Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 215344 Fan, Rotor Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 212161 Adapter, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 202771 Baffle, Engine Adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 142156 Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 170861 Stud, Stl .375−16 X 17.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 205725 Brushholder Assy, Generator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 010910 Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 010909 Nut, 375−16 .56hex .46h Stl Pld Elastic Stop Nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 136343 Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 218049 Endbell (includes) (Prior to LF071520) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 223889 Endbell (includes) (Eff w/ LF071521 Thru LF279650) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 216532 Tolerance Ring, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 217046 Endbell (includes) (Eff w/LF279651) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 216532 Tolerance Ring, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 214017 Bracket, Terminal Strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 173734 Link, Jumper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 887-B


14

12

11

10

9

7

6

3

4

5

1

2

16

17

18

8

13

15

Figure 12-3. Generator

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Orderlabel individually or as part of Label Kit 217221.



� Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-rately or as part of the associated wiring harness.

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Wiring Harnesses

Quantity

217875 Harness, Wrg Ignition (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 15 113752 Conn, Rect Mini 045 10skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC 5 113634 Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 24 117865 Conn, Rect Mini 045 14skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 8 177859 Conn, Body 5 Terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202660 Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218733 Harness, Remote Control 14Pin (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RC 4 134735 Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG 14 113751 Conn, Rect Mini 045 8skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CB 4 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218729 Harness, Wrg Power Board (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 27 176121 Conn, Rect Univ 084 2p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 25 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 31 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 26 066104 Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218731 Harness, Wrg Interconnecting (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 17 117037 Conn, Rect Mini 045 2skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 23 117037 Conn, Rect Mini 045 2skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 21 113752 Conn, Rect Mini 045 10skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 16 116513 Conn, Rect Mini 045 12skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217747 Plugs, w/Leads (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 6 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG13 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217305 Harness, Wrg Interconnecting (AC/DC Units) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG 12 130693 Conn,Rect Mini 045 5skt 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 135556 Plug, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2012 Miller Electric Mfg. Co.

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125

For International Locations Visitwww.MillerWelds.com

Documents

TRAILBLAZER302 (LE246322)