HOBART CHAMPION 10,000 t945f - Hob PDF

TM-945F 2006−08
Eff. w/Serial Number KK254680

Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion 10,000
™
INFORMATION ON OLDER UNITS
Note 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
Note Engine manufacturer changed engine name from Onan OHV #100 3595 to Robin EH65
Prior to LE139818 Engine Maintenance Label refers to Onan
Eff w/LE139818 Engine Maintenance Label refers to Robin
Note Generator excitation circuit protection change:

Prior to LC654122 − Fuse F1
Eff w/LC654122 − Circuit Breaker CB4
Champion 10,000 TM-945

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-4. Fuel Consumption (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-2. Engine Prestart Checks (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-5. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 5 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-3. Amperage Selection Table For Stick (SMAW) Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6-1. Standard Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6-2. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 16
SECTION 7 − MAINTENANCE (ROBIN-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7-1. Routine Maintenance (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7-2. Maintenance Label (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7-3. Servicing Air Cleaner (Robin−Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7-4. Overload Protection (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-5. Servicing Optional Spark Arrestor (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . 21
7-7. Adjusting Engine Speed (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 8 − MAINTENANCE − (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8-3. Servicing Air Cleaner (Kohler−Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-4. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-5. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-7. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 9 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10-2. Troubleshooting Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-3. Waveforms For Section 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TABLE OF CONTENTS
10-4. Field Current Control Board PC1 Testing Information Prior To LA330495 (Onan) And LA330472 (Kohler)
39
10-5. Field Current Control Board PC1 Test Point Values Prior To LA330495 (Onan) And LA330472 (Kohler) . .
40
10-6. Field Current Control Board PC1 Testing Information Eff w/LA330495 Thru LB171606 (Onan) And Eff
w/LA330472 Thru LB163304 (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10-7. Field Current Control Board PC1 Test Point Values Eff w/LA330495 Thru LB171606 (Onan) And Eff w/
LA330472 Thru LB163304 (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10-8. Field Current Control Board PC1 Testing Information Eff w/LB171607 (Robin) And LB163305 (Kohler)
And Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-9. Field Current Control Board PC1 Test Point Values Eff w/LB171607 (Robin) And LB163305 (Kohler) And
Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-10. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10-11. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11-1. Disassembly/Reassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11-2. Disassembly/Reassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 13 − PARTS LIST FOR KK254680 THRU LA199099 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SECTION 14 − PARTS LIST FOR LA199100 THRU
LB098425 (ONAN) AND LA199100 THRU LB104240 (KOHLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SECTION 15 − PARTS LIST FOR LB098426 THRU
LC089660 (ONAN) AND LB104241 THRU LC089660 (KOHLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SECTION 16 − PARTS LIST FOR LC089661 THRU LC654121 (ONAN & KOHLER) . . . . . . . . . . . . . . . . . . . . 94
SECTION 17 − PARTS LIST EFF W/LC654122 THRU LE385381 (ROBIN & KOHLER) . . . . . . . . . . . . . . . . . 100
SECTION 18 − PARTS LIST EFF W/LE385382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage

OM-945AA - 2006−07, safety_rtm 3/06
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
Means “Note”; not safety related. to avoid the hazards.
1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see STATIC (ESD) can damage PC boards.
the symbol, watch out, and follow the related instructions to
Put on grounded wrist strap BEFORE handling
avoid the hazard.
boards or parts.
Y Only qualified persons should test, maintain, and repair this Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.

Do not touch live electrical parts. ENGINE EXHAUST GASES can kill.
Stop engine before testing or repairing unit un- Do not breathe exhaust fumes.
less the procedure specifically requires an en- Use in open, well-ventilated areas, or vent ex-
ergized unit. haust outside and away from any building air in-
Insulate yourself from ground by standing or working on dry insu- takes.
lating mats big enough to prevent contact with the ground.
Do not leave live unit unattended.
When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters. Stop engine and let it cool off before checking or
adding fuel.
Stop engine on inverter and discharge input capacitors according
Do not add fuel while smoking or if unit is near
to instructions in Troubleshooting Section before touching any
any sparks or open flames.
parts.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.

Keep away from moving parts such as fans,
belts, and rotors.
BATTERY EXPLOSION can BLIND.
Have only qualified people remove doors,
panels, covers, or guards for maintenance Always wear a face shield, rubber gloves, and
and troubleshooting as necessary. protective clothing when working on a battery.
Keep hands, hair, loose clothing, and tools away from moving Stop engine before disconnecting or connect-
parts. ing battery cables.
Before working on generator, remove spark plugs or injectors Do not allow tools to cause sparks when working on a battery.
to keep engine from kicking back or starting. Do not use welder to charge batteries or jump start vehicles.
Block flywheel so that it will not turn while working on genera- Observe correct polarity (+ and −) on batteries.
tor components. Disconnect negative (−) cable first and connect it last.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
FLYING METAL or DIRT can injure eyes. BATTERY ACID can BURN SKIN and EYES.
Wear safety glasses with side shields or face
Do not tip battery.
shield during servicing.
Be careful not to short metal tools, parts, or Replace damaged battery.
wires together during testing and servicing. Flush eyes and skin immediately with water.
Champion 10,000 TM-945 Page 1

STEAM AND HOT COOLANT can burn. TILTING OR TIPPING can cause injury.
If possible, check coolant level when engine is Do not put any body part under unit while lifting.
cold to avoid scalding. Always use proper equipment (hoists, slings,
Always check coolant level at overflow tank, if chains, blocks, etc.) of adequate capacity to lift
present on unit, instead of radiator. and support components (stator, rotor, engine,
If the engine is warm, checking is needed, and etc.) as needed during job.
there is no overflow tank, follow the next two PINCH POINTS can injure.
statements.
Be careful when working on stator and rotor assemblies.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap. H.F. RADIATION can cause interference.
MAGNETIC FIELDS can affect pacemakers. High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
Pacemaker wearers keep away from servicing communications equipment.
areas until consulting your doctor.
Have only qualified persons familiar with elec-
tronic equipment perform this installation.
The user is responsible for having a qualified electrician prompt-
FALLING UNIT can cause injury. ly correct any interference problem resulting from the installa-
tion.
Use lifting eye to lift unit and properly installed
accessories only. Do not exceed maximum lift If notified by the FCC about interference, stop using the equip-
eye weight rating (see Specifications). ment at once.
Lift and support unit only with proper equip- Have the installation regularly checked and maintained.
ment andcorrect procedures. Keep high-frequency source doors and panels tightly shut, keep
Securely attach components to lifting equip- spark gaps at correct setting, and use grounding and shielding to
ment. minimize the possibility of interference.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit. OVERUSE can cause OVERHEATING.
HOT PARTS can cause severe burns. Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
Do not touch hot engine parts bare-handed. starting to weld again.
Allow cooling period before working on Do not block or filter airflow to unit.
equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and READ INSTRUCTIONS.
clothing to prevent burns. Use Testing Booklet (Part No. 150 853) when
servicing this unit.
SHOCK HAZARD from testing.
Consult the Owner’s Manual for welding safety
Stop engine before making or changing meter precautions.
lead connections. Use only genuine replacement parts from the
Use at least one meter lead that has a self- manufacturer.
retaining spring clip such as an alligator clip. Reinstall injectors and bleed air from fuel system according to
Read instructions for test equipment. engine manual.
1-3. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Y Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from
Research Council concluded that: “The body of evidence, in the operator as practical.
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.” 5. Connect work clamp to workpiece as close to the weld as
However, studies are still going forth and evidence continues to be possible.
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when About Pacemakers:
welding or cutting. Pacemaker wearers consult your doctor before welding or going near
To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above
procedures: procedures is recommended.
TM-945 Page 2 Champion 10,000
SECTION 2 − DEFINITIONS
2-1. Symbol Definitions
Stop Engine Fast Fast/Slow Slow (Idle)

(Run, Weld/Power) (Run/Idle)
Start Engine Read Operator’s

Manual A Amperes V Volts
Engine Oil Fuel Battery (Engine) Engine
Engine Choke Check Valve Circuit Protector Temperature

Clearance
Positive Negative Alternating Current Output

(AC)
h s
Hours Seconds Time Protective Earth
(Ground)
Welding Arc Stick (SMAW) Fuse

(Electrode)
SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Note This unit uses either a Robin or a Kohler engine. Differences between models are noted
throughout this manual.
Rated Maximum
Welding Weld Output Single-Phase Fuel
Welding Open Circuit Engine
Mode Range Generator Power Rating Capacity
Output Voltage
230 A, 25 V, Robin
30% Duty Air-Cooled, Two-Cylinder,
Cycle Peak: 10 kVA/kW,
84/42 A, Four-Cycle, 22 HP
210 A, 25 V, 120/240 V AC, Gasoline Engine
60% Duty 10 gal
CC/DC 50 − 230 A 73 60 Hz or
Cycle (38 L) Tank
Kohler CH-20
170 A, 25 V, Continuous: 9.5 kVA/kW
Air-Cooled, Two-Cylinder,
(while not welding)
100% Duty Four-Cycle, 20 HP
Cycle Gasoline Engine

3-2. Dimensions, Weights, and Operating Angles
Dimensions
Height 33-1/2 in (851 mm)

A
Width 18-1/2 in (470 mm) B
C
Depth 38 in (965 mm) Do not exceed tilt angles
g or engine
g could
G
D be damaged or unit could tip.
tip
A 18 in (457 mm) 4 HOLES
Do not move or operate unit where it could
B 16-9/16 in (421 mm) tip.
C 23/32 in (18 mm)
D 3 in (76 mm)
E 31-1/2 in (800 mm) F E

25°
F 37-1/2 in (953 mm)
G 13/32 in (10 mm) Dia. 25° 25°
Weight 25°
Robin-Powered Unit: 445 lb (202 kg)
Kohler-Powered Unit: 444 lb (201 kg)
Lifting Eye Weight Rating

Engine End
802 855
1280 lb (580 kg)
3-3. Generator Power Curve

The generator power curve shows
the generator power in amperes
available at the receptacles.
197 252

3-4. Fuel Consumption (All Models)
197 254
3-5. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
100% Duty Cycle at 170 Amperes CC/DC
6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting

60% Duty Cycle at 210 Amperes CC/DC 30% Duty Cycle at 230 Amperes CC/DC
197 148

3-6. Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
197 253
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 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)

SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Do not weld on base. Welding

on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Do not lift unit from end. Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
OR
Do not mount unit by support-
ing the base only at the four
mounting holes. Use cross-
supports to adequately sup-
port unit and prevent damage
to base.
Location / Airflow Clearance Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
OR If unit does not have GFCI re-
ceptacles, use GFCI-protected
extension cord.
Mounting:
1 Cross-Supports
18 in
Mount unit on flat surface or use
(460 mm)
cross-supports to support base.
18 in
18 in (460 mm) Grounding:
(460 mm) 2 Equipment Grounding Terminal
(On Front Panel)
3 Grounding Cable (Not Supplied)
4 Metal Vehicle Frame
18 in 18 in Connect cable from equipment
(460 mm) (460 mm) ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
Mounting
OR
Inadequate support.
Do not use flexible mounts. 1
Grounding
2
3 Bed liners, shipping skids, and some running
GND/PE gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
Electrically bond generator frame to

vehicle frame by metal-to-metal contact.
4
install2 11/04 − Ref. 800 652 / Ref. 800 477-A / 803 274

4-2. Engine Prestart Checks (Robin-Powered Units)
Check all fluids daily. Engine must be cold and
on a level surface. Unit is shipped with 10W30
engine oil.
Engine stops if oil pressure gets too low.
Follow run-in procedure in engine manual.
Full This unit has a low oil pressure shutdown
switch. However, some conditions may
Full cause engine damage before the engine
shuts down. Check oil level often and do
not use the oil pressure shutdown system
to monitor oil level.
Gasoline Fuel
To help prime the fuel system at initial start-up,
fill tank with fresh fuel (see maintenance label
for specifications). Always leave filler neck
empty to allow room for expansion (see fuel
tank window on base). Check fuel level on a
cold engine before use each day.
Oil
Do not exceed the ”Full” mark on the oil
level dipstick. The fuel pump may operate
erratically if crankcase is overfilled.
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick, add
oil (see maintenance label).
To improve cold weather starting:
Keep battery in good condition. Store bat-
tery in warm area.
Use correct grade oil for cold weather.

802 353-G
4-3. Engine Prestart Checks (Kohler-Powered Units)

Check all fluids daily. Engine must be cold and
on a level surface. Unit is shipped with 10W30
engine oil.
Engine stops if oil pressure gets too low.
Follow run-in procedure in engine manual.
Full
This unit has a low oil pressure shutdown
Full switch. However, some conditions may
cause engine damage before the engine
shuts down. Check oil level often and do
not use the oil pressure shutdown system
to monitor oil level.
Gasoline
Fuel
To help prime the fuel system at initial start-up,
fill tank with fresh fuel (see maintenance label
for specifications). Always leave filler neck
empty to allow room for expansion (see fuel
tank window on base). Check fuel level on a
cold engine before use each day.
Oil
Do not exceed the ”Full” mark on the oil
level dipstick. The fuel pump may operate
erratically if crankcase is overfilled.
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick, add
oil (see maintenance label).
To improve cold weather starting:
Keep battery in good condition. Store bat-
tery in warm area.
Use correct grade oil for cold weather.

802 339-G

4-4. Activating The Dry Charge Battery (If Applicable)
Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1 Vent Caps
2 2 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1 3 Well
Fill each cell with electrolyte to
bottom of well (maximum).
Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
4 Battery Charger
Read and follow all instruc-
tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
4
When electrolyte is low, add
only distilled water to cells to
maintain proper level.
5 A For 30 Minutes
OR
+
−
Tools Needed: 30 A For 12 Minutes
drybatt1 6/05 − S-0886
4-5. Connecting the Battery
Connect negative (−)

cable last.
+ −
Tools Needed:
1/2 in
Ref. 226 427-A / Ref. 802 341 / Ref. S-0756-D

4-6. Installing Exhaust Pipe
Engine backfire can cause se-
vere burns or other injuries.
Do not point exhaust pipe to-
ward control panel. Keep
away from exhaust outlet.
Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in 801 681 / Ref. 226 427-A
4-7. Weld Output Terminals

1 Negative (−) Weld Output
Terminal
2 Positive (+) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder cable to Positive (+)
terminal.
For Direct Current Electrode Nega-
tive (DCEN), reverse cable
connections.
Tools Needed:
3/4 in
1 2
802 353-G / Ref. 226 427-A

4-8. Connecting To Weld Output Terminals
Stop engine.
Failure to properly connect
weld cables may cause ex-
cessive heat and start a fire,
or damage your machine.
1 Weld Output Terminal
2 Supplied Weld Output
Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld
4
output terminal. Slide weld cable
1
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per bar. Do not place anything be-
Do not place
anything between tween weld cable terminal and
weld cable terminal copper bar. Make sure that the
and copper bar. surfaces of the weld cable termi-
nal and copper bar are clean.
Tools Needed:
3
3/4 in
Correct Installation Incorrect Installation
803 778-A / Ref. 226 427-A
4-9. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Weld Output Welding
Duty Duty 10 − 100% Duty Cycle
Terminals Amperes
Cycle Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
Turn off power before
connecting to weld 2 ea. 2/0 2 ea. 2/0
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
output
p terminals. (2x70) (2x70)
Do not use worn, dam- 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
aged, undersized, or 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
poorly spliced cables.
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
* This chart is a general guideline and may not suit all applications. If cable overheating occurs, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 1-800-332-3281.

SECTION 5 − OPERATING THE WELDING GENERATOR
NOTE If the unit is extremely overloaded, weld and generator power will stop. Turn unit off and
restart to reset the generator protection circuit and restore weld generator power output.
If the rated output of the unit is exceeded, engine speed may vary rapidly until the weld or
generator load is reduced.
5-1. Front Panel Controls
1
3
4 2
Ref.226 427-A
1 Engine Control Switch To Start: pull out choke and turn Engine Con- To Stop: turn Engine Control switch to Off
trol switch to Start position. Release switch position.
Use switch to start engine, select speed, and and slowly push choke in when engine starts.
stop engine. In Run/Idle position, engine runs 3 Engine Hour Meter
at idle speed at no load, and weld/power If the engine does not start, let the engine 4 Amperage Control
speed under load. In Run position, engine come to a complete stop before attempt-
ing restart. Use control to select weld amperage. Select
runs at weld/power speed.
amperage according to electrode being used
2 Engine Choke Control During cold weather some gasoline en- (see Section 5-3). Control may be adjusted
gines encounter difficulties that are easily while welding. Control does not affect gener-
Use control to change engine air-fuel mix. remedied. See Section 5-2 and 10-1. ator power output.

5-2. Cold Weather Engine Operation
1 Engine Control Switch
Carburetor Icing
Carburetor icing causes the unit to drop below the normal idle speed and then
stall. This condition occurs when the temperature is near freezing and the rela-
1 Infrequently tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu-
Loaded 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 0F).
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 freezing
or ice in the carburetor. All of these cause operating problems. Due to ice in
the lines, the engine may not restart until it is warmed to above freezing.
Frequently
Load engine and reduce idle times to prevent engine shutdowns.
Loaded
Use an electric fuel pump to avoid pulse line freezing.
Install engine cold−weather kit.
Both Kohler (1-800-544-2444) and Robin (1-800-277-6246) offer kits for cold
weather operation. The user can install these kits. Both kits pull heated air from
the muffler surface into the carburetor and shut the cold air off. This increases
engine temperature during operation in both idle and high speed.
When the ambient temperatures become warmer (above 45_F) the air
flow will have to be returned to normal.
Ref. 226 427-A
5-3. Amperage Selection Table For Stick (SMAW) Electrodes

Use table on front panel to se-
lect correct amperage for the
electrode being used.
Ref. 202 069-A

SECTION 6 − OPERATING AUXILIARY EQUIPMENT
NOTE If the unit is extremely overloaded, weld and generator power will stop. Turn unit off
and restart to reset the generator protection circuit and restore weld and generator
power output.
If the rated output of the unit is exceeded, engine speed may vary rapidly until the
weld or generator power load is reduced.
The welding generator provides power while welding and with the Amperage
control in any position. However, under these conditions equipment connected to
the welding generator may be subject to larger than normal voltage fluctuations. It
is recommended that only lamps be powered under these conditions.
6-1. Standard Receptacles

If unit does not have GFCI re-
ceptacles, use GFCI-
protected extension cord.
1 120/240 V 50 A AC Recep-
tacle RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maxi-
mum output is 10 kVA/kW.
1 5 2 6 3 2 120 V 20 A AC Duplex Recep-
tacle RC2
3 120 V 20 A AC Duplex Recep-
tacle RC3
RC2 and RC3 supply 60 Hz single-
phase power at weld/power speed.
Maximum output from RC2 or RC3
is 2.4 kVA/kW.
4 Supplementary Protector CB1
CB1 protects the ac receptacles
from overload. If CB1 opens, the ac
receptacles do not work.
Move CB1 toggle switch to On
position to reset. If supplemen-
tary protector continues to
open, contact Factory
Authorized Service Agent.
CB2 protects RC2 and CB3 pro-
tects RC3 from overload. If a sup-
plementary protector opens, the re-
ceptacle does not work.
Press button to reset. If supple-
mentary protector continues to
open, contact Factory
4 Authorized Service Agent.
Combined output of all receptacles
limited to 10 kVA/kW rating of the
generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
21 A is available at the 240V
receptacle:
2 x (120 V x 20 A) + (240 V x 21 A)
= 10 kVA/kW (approx.).
Ref. 226 427-A

6-2. Optional Generator Power Receptacles
If unit does not have GFCI re-
ceptacles, use GFCI-
protected extension cord.
Combined output of all receptacles
limited to 10 kVA/kW rating of the
generator.
GFCI Receptacle Option
1 120 V 20 A AC GFCI Recep-
tacles GFCI2 and GFCI3
GFCI2 and GFCI3 supply 60 Hz
1 single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/kW. Cir-
cuit protection is the same as stan-
dard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.
At least once a month, run
engine at weld/power speed
and press Test button to verify
GFCI is working properly.
Ref. 226 427-A
Notes
Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
6-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1 Plug Wired for 120/240 V,
7 3-Wire Load
Current Available in Amperes When wired for 120 V loads, each
duplex receptacle shares a load
240 V Each 120 V Duplex with one half of 240 V receptacle.
Receptacle* Receptacle
2 Plug Wired for 240 V, 2-Wire
0 20 Load
3 1
5 20 3 Neutral (Silver) Terminal
10 20 4 4 Load 1 (Brass)Terminal
15 20 5 Load 2 (Brass) Terminal
20 20 6 Ground (Green) Terminal
25 15 7 Amperes Available using
30 10 120/240 V Plug
120V
35 5 120V 5
40 0 240V 6
V x A = Watts Tools Needed:
*One 240 V load or two 120 V loads. 2
3
4
240V
6 5
240 V AC
120 V AC 120 V AC
plug1 11/03 − 120 813-D

SECTION 7 − MAINTENANCE (ROBIN-POWERED UNITS)
7-1. Routine Maintenance (Robin-Powered Units)
Stop engine before maintaining.
See Engine Manual and Maintenance Label
Recycle engine for important start-up, service, and storage
fluids. information. Service engine more often if
used in severe conditions.
= Check = Change = Clean

= Replace Reference
* To be done by Factory Authorized Service Agent
Every Section 4-2
8
Hours
Fuel Level Oil Level Oil, Fuel Spills

Every Section 7-5
20
Hours
Spark Arrestor Screen

Every Section 7-3
25
Hours
Air Cleaner Wrapper

Every
50
Hours
Weld Terminals
Every Engine
100 Manual,
Hours Section 7-6,
7-3
Battery Terminals Cooling System Oil

Air Cleaner Element
Every Engine
200 Manual,
Hours Section 7-6

Unreadable Labels Spark Plug Gap Oil Filter
Fuel Filter
Every Engine
500 Manual
Hours

Weld Cables Slip Rings* Valve Clearance*

Brushes*
Every
1000 OR
Hours
Inside Unit

7-2. Maintenance Label (Robin-Powered Units)

7-3. Servicing Air Cleaner (Robin−Powered Units)
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1 Wrapper
Wash wrapper with soap and water
1 solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
2 evenly into wrapper. Squeeze out
excess oil.
2 Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 11/04 −803 070 / S-0759
Notes
Over 80,000 trained

7-4. Overload Protection (Robin-Powered Units)
Tools Needed: Stop engine. Disconnect nega-
tive (−) battery cable.
If the unit is extremely over-
loaded, weld and generator pow-
3/8 in er will stop. Turn unit off and re-
start to reset the generator
protection circuit and restore weld
and generator power output.
If the rated output of the unit is ex-

ceeded, engine speed may vary
rapidly until the weld or generator
power load is reduced.
1 Circuit Breaker CB4 (See Parts
List)
1
CB4 protects the generator excitation
circuit. If CB4 opens, there is no/low
weld and generator power output.
Press button to reset breaker.
2 Fuse F6 (See Parts List)
F6 protects the engine wiring system.
If F6 opens, the engine does not
crank. If F6 opens while the engine is
running, the engine stops.
Replace fuse if open. Reinstall cover
2 before operating.
If a fuse or circuit breaker opens,
it usually indicates a more serious
problem exists. Contact a Factory
Authorized Service Agent.
802 342 / Ref. 802 353-G
7-5. Servicing Optional Spark Arrestor (Robin-Powered Units)

Stop engine and let cool.
1 Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
Tools Needed:
1/4 in
Ref. 801 682-A / Ref. 802 353-A

7-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)
1 Oil Drain Valve
2 1/2 ID x 7 in Hose
3 Oil Filter
Change engine oil and filter ac-
cording to engine owner’s
manual.
Close valve and valve cap
before adding oil and
running engine.
Fill crankcase with new oil to full
Full mark on dipstick (see Section
7-2).
4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any
spilled fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten
4 connections as neces-
sary, and wipe up fuel.
Tools Needed:
802 353-G / S-0842

7-7. Adjusting Engine Speed (Robin-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 ± 100 rpm Start engine and run until warm.
3700 ± 50 rpm Remove wrapper to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.
1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust
1 solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight-
en mounting screws. Be sure sole-
3 noid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4 Jam Nut
5 Lock Nut
6 Weld/Power Speed
Adjustment Screw
Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
2 nut, and then tighten lock nut.
Stop engine.
Reinstall wrapper.
4
6 5
Tools Needed:
10 mm
8 mm 802 353-G / 802 457

SECTION 8 − MAINTENANCE − (KOHLER-POWERED UNITS)
8-1. Routine Maintenance (Kohler-Powered Units)
Stop engine before maintaining.
See Engine Manual and Maintenance Label
Recycle engine for important start-up, service, and storage
fluids. information. Service engine more often if
used in severe conditions.
= Check = Change = Clean

= Replace Reference
* To be done by Factory Authorized Service Agent
Every Section 4-3
8
Hours
Fuel Level Oil Level Oil, Fuel Spills

Every Section 8-5
20
Hours
Spark Arrestor Screen

Every Section 8-3
25
Hours
Air Cleaner Wrapper

Every
50
Hours
Weld Terminals
Every Engine
100 Manual,
Hours Section 8-3,
8-6
Battery Terminals Cooling System Oil

Air Cleaner Element
Every Engine
200 Manual,
Hours Section 8-6

Unreadable Labels Spark Plug Gap Oil Filter
Fuel Filter
Every Engine
500 Manual
Hours

Weld Cables Slip Rings*

Brushes*
Every
1000 OR
Hours
Inside Unit

8-2. Maintenance Label (Kohler-Powered Units)

8-3. Servicing Air Cleaner (Kohler−Powered Units)
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1 Wrapper
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
1
evenly into wrapper. Squeeze out
excess oil.
2 2 Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 11/04 − 802 772 / S-0759
Notes
Over 80,000 trained

8-4. Overload Protection (Kohler-Powered Units)
Stop engine.
Tools Needed:
If the unit is extremely over-
loaded, weld and generator pow-
er will stop. Turn unit off and re-
start to reset the generator
3/8 in protection circuit and restore
weld and generator power out-
put.
If the rated output of the unit is ex-

ceeded, engine speed may vary
rapidly until the weld or generator
power load is reduced.
1 Circuit Breaker CB4 (See Parts
List)
1 CB4 protects the generator
excitation circuit. If CB4 opens, there
will be no/low weld and generator
power output.
Press button to reset breaker.
2 Fuse F6 (See Parts List)
F6 protects the engine wiring
harness. If F6 opens, the engine
does not crank. If F6 opens while the
engine is running, the engine stops.
Replace fuse if open. Reinstall panel
before operating unit.
2
If a fuse or circuit breaker opens,
it usually indicates a more seri-
ous problem exists. Contact a
Factory Authorized Service
Agent.
Ref. 801 221-B / Ref. 802 353-G
8-5. Servicing Optional Spark Arrestor (Kohler-Powered Units)

1 Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
Tools Needed:
1/4 in
Ref. 801 695-A / Ref. 802 339-A

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)
1 Oil Drain Valve
2 1/2 ID x 7 in Hose
3 Oil Filter
Change engine oil and filter accord-
ing to engine owner’s manual.
Close valve and valve cap
before adding oil and
running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
Full 4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up fuel.
4
Tools Needed:
802 339-G / S-0842

8-7. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 ± 50 rpm Start engine and run until warm.
Remove wrapper to access speed
3700 ± 50 rpm adjustments.
Idle Speed Adjustment
Move Engine Control switch to
1 Run/Idle position.
1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
5 idle speed. If necessary, back out
idle speed screw so solenoid can
2
4 be moved to correct position. Tight-
en mounting screws. Be sure sole-
noid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4 Weld/Power Speed
Adjustment Nut
5 Lock Nut
Loosen lock nut. Turn adjustment
nut until engine runs at weld/power
3 speed. Tighten lock nut.
Stop engine.
Reinstall wrapper.
Top View
Tools Needed:
1/4, 3/8 in
802 339-G / 801 209-A

Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 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)

SECTION 9 − THEORY OF OPERATION
1 Engine
10
Supplies force to turn revolving
fields. Generator
Power AC
2 Throttle Solenoid TS1 Receptacles
Decreases engine speed to idle
(2200 rpm) when energized.
3 Revolving Field (Rotor) 2 9
Turns at 3700 rpm maximum (60 Throtttle
Hz) for weld and power. The speed Solenoid Generator Power
and excitation current of the field TS1 Circuit
(Pull To Idle) Breakers
coils determine voltages in stator
windings.
4 Stator Windings
Supply power to exciter, generator 1 3 4
power, and weld circuits. Generator Power
Revolving
5 Fuse F1 Prior to LC654122 Engine Field
Weld
Circuit Breaker CB4 Eff w/ (Rotor) Stator Windings
LC654122
Exciter
Protects stator excitation windings
from overload.
6 Integrated Rectifier SR2 5
Changes ac output of stator Fuse F1 OR

windings to dc to supply excitation Circuit
Engine Speed Feedback Signal
current to the exciter revolving field. Breaker CB4

7 Control Board PC1
Adjusts weld output by changing
Excitation DC Supply
revolving field current after 6

comparing feedback to amperage
setting of R1. Integrated
Rectifier
Uses current feedback signal for SR2
AC Supply
foldback circuit to prevent stator

failure from short-circuit conditions.
Uses voltage feedback signal to
maintain open-circuit and genera- 7
tor power voltages regardless of
Current Control R1 setting.
Stops weld and power output when
generator is overloaded.
Control Board PC1
Controls engine speed. When sig-
nal is received from current trans-
former CT1, PC1 de−energizes
TS1 to increase engine speed to
weld/power (3700 rpm). Without a
signal from CT1, engine runs at idle
speed (2200 rpm). 8
8 Amperage Control R1
Amperage
Changes output of stator weld Control R1
windings by adjusting field current
level in revolving field.
9 Generator Power Circuit
Breakers
Protect ac receptacles from over-
load.
10 Generator Power AC
Receptacles
Provide connection points and
power for auxiliary equipment.

11 Main Rectifier SR1
Changes ac weld current to dc.
12 Stabilizer DC-Z
Smooths weld output current.
13 Current Transducer LEM
Provides weld current feedback
signal to control board PC1.
14 Positive (+) And Negative (−)
Weld Output Terminals
Provide weld output.
11
Main Rectifier
SR1
Voltage Feedback Signal

Voltage Feedback Signal
12 13
Current
Stabilizer DC-Z Transducer
LEM
Current Feedback Signal
14 14
Positive (+) Negative (−)

Weld Output Weld Output
Terminal Terminal
Electrode Work
AC Or DC Control Circuits
Weld Current Circuit
Mechanical Coupling
Magnetic Coupling

SECTION 10 − TROUBLESHOOTING
NOTE If the unit is extremely overloaded, weld and generator power stops and the LED
lights on circuit board PC1. Turn unit off and restart to reset the generator
protection circuit and restore weld and generator power output.
If the rated output of the unit is exceeded, engine speed may vary rapidly until the
weld or generator power load is reduced.
10-1. Troubleshooting
See Section 10-2 for test points and values

and Section 13 and following for parts
location.
Use MILLER Testing Booklet (Part No. 150

853) when servicing this unit.
A. Welding
Trouble Remedy
No weld output; generator power out- Check control settings.
put okay at ac receptacles.
Check weld connections.

Check main rectifier SR1, and replace if necessary.
Disconnect stator leads 70 and 71, and check continuity between leads. Replace stator if necessary.
Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-4, 10-6, or 10-8).
No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.
put at ac receptacles.
Unit overloaded. Stop unit and reduce load. Restart unit to reset generator protection circuit and resume
operation. (Circuit board PC1 LED1 lights when unit is overloaded. See Section 10-4.)
Prior to LC654122: Check fuse F1 and replace if open (see Section 7-4 or 8-4). Prior to LA199100, fuse
F1 was located inside unit on lower left side.
Eff w/LC654122: Reset circuit breaker CB4.
If F1 or CB4 continue to open, check integrated rectifier SR2 and the rotor.
Check plug PLG6 connection.
Check integrated rectifier SR2, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 10-10).
Disconnect leads 21 and 26 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Disconnect stator excitation leads 28 and 29, and check continuity between leads. Replace stator if
necessary.
10-4, 10-6, or 10-8).
Low weld output. Check control settings.

Check engine speed, and adjust if necessary (see Section 7-7 or 8-7).
Service air cleaner according to engine manual.
10-4, 10-6, or 10-8).
High weld output. Check control settings.

Check connections of current transducer LEM. Check input and output voltages. Replace LEM if
necessary.

Trouble Remedy
High weld output (continued). Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-4, 10-6, or 10-8).
Erratic weld output. Check control settings.

Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check main rectifier SR1, and replace if necessary.
Check stabilizer DC-Z for signs of failure. Check continuity across windings, and check for proper
connections. Replace DC-Z if necessary.
B. Generator Power
Trouble Remedy
No generator power output at ac Reset circuit breakers (see Section 6-1 or 6-2).
receptacles; weld output okay.
okay
Press optional GFCI receptacle Reset button (see Section 6-2).
Check resistance of generator power windings between leads 50 and 51, and leads 52 and 53. Replace
stator if necessary.
No generator power at ac receptacles; Be sure all equipment is disconnected from receptacles when starting unit.
no weld output.
Unit overloaded. Stop unit and reduce load. Restart unit to reset generator protection circuit and resume
operation. (Circuit board PC1 LED1 lights when unit is overloaded. See Section 10-4, 10-6, or 10-8.)
Check plug PLG6 connection.
Disconnect leads 21 and 26 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Disconnect stator excitation leads 28 and 29, and check continuity between leads. Replace stator if
necessary.
10-4, 10-6, or 10-8).
High generator power output at ac Check engine speed, and adjust if necessary (see Section 7-7 or 8-7).
receptacles.
Low generator power output at ac Prior to LC654122: Check fuse F1 and replace if open (see Section 7-4 or 8-4). Prior to LA199100, fuse
receptacles. F1 was located inside unit on lower left side.
Erratic generator power output at ac Check fuel level.
receptacles.
Check engine speed and adjust if necessary (see Section 7-7 or 8-7).
Check receptacle wiring and connections.

C. Engine
Trouble Remedy
Engine will not crank. Check fuse F6, and replace if open (see Section 7-4 or 8-4).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG4 and plug PLG8 connections.
Check continuity of Engine Control switch S2, and replace if necessary.
Engine will not start. Check fuel level.
Check battery voltage.
Check battery connections and tighten if necessary.
Check oil level (see Section 4-2 or 4-3).
Check low oil pressure shutdown switch (see Parts List for location).
Check fuel shutoff solenoid FS1 according to engine manual.
Engine starts, but stops when Engine Check oil level.

Control switch returns to Run position
position.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.
Check low oil pressure shutdown switch (see Parts List for location).
Engine stopped during normal Check fuel level.

operation
operation.
Check oil level (see Section 4-2 or 4-3).
Check fuse F6, and replace if open (see Section 7-4 or 8-4).
Check low oil pressure shutdown switch (see Parts List for location)
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Check fuel shutoff solenoid FS1 according to engine manual.
Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Engine idles, but does not come up to Check current transformer CT1, and replace if necessary.
weld speed.
10-4, 10-6, or 10-8).
Engine speed varies rapidly under Reduce generator power load at ac receptacles.
heavy generator power load.
Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.
Tune-up engine according to engine manual.
Engine does not return to idle speed. Remove weld and generator power loads.
Check throttle linkage for smooth, non-binding operation.
Check current transformer CT1, and replace if necessary.
Check continuity of Engine Control switch S2, and replace if necessary.
Check voltage at throttle solenoid TS1, and check TS1 resistance. Replace TS1 if necessary
10-4, 10-6, or 10-8).

Trouble Remedy
During operation in near freezing tem- Treat fuel with isopropyl alcohol de-icer product.
peratures, engine starts and goes to
idle but stalls after a few minutes.
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- Install engine manufacturer’s kit for cold-weather operation.
er, engine starts and goes to idle but
stalls after a few minutes.
Notes

10-2. Troubleshooting Circuit Diagram For Welding Generator
Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine
(no warm-up); no load; weld/power
rpm unless noted
c) Reference − single arrow: reference to
circuit common (lead 33); double arrow:
reference to points indicated
d) Wiring Connections − see Section 12
V1 +60 volts dc OCV
V1 +70 volts dc OCV
V2 228 volts ac (no load)
220 volts ac (load) Prior To LE654122
See Section
Fuse F1
V2 248 volts ac (no load) 10-4, 10-6, or
236 volts ac (load) 10-8 for PC1
data
110 volts ac (load)
V6
116 volts ac (load)
V4 DC output to revolving field: V7
+15 volts dc (idle rpm)
+14.2 volts dc (weld/power rpm)
V4 DC output to revolving field
+17 volts dc (idle rpm)
+16.2 volts dc (weld/power rpm)
V5 AC output from exciter winding:
86 volts ac (R1 at min. with 45 A, 25 V
load applied)
143 volts ac (R1 at max. with 230 A, 25 V
load applied)
V6 DC output from SR2:
111 volts ac (R1 at min. with 45 A, 25 V
load applied)
190 volts ac (R1 at max. with 230 A,
25 V load applied)
V7 R1 input to PC1: 10 volts dc (R1 at min); 0
volts dc (R1 at max)
V8 S2 in Run/Idle position: 11.6 volts dc
S2 in Run position: 0 volts dc
V9 Current sensing voltage with 200 watt light
bulb load applied: 2.9 volts ac
V10 AC input to regulator: 22 volts ac
(idle rpm) V12
36 volts ac (weld/power rpm)
V11 DC output from regulator: +14.2 volts dc
V12 DC input to PC1: +12-14 volts dc with S2
in Run/Idle position
V13 +15 volts dc
V14 −15 volts dc
V15 +1 volt dc per 40 amperes weld output
Prior to LB078855 (Robin), LB098320 (Kohler) R1,

V8 V11
Eff w/LB078855 (Robin), LB098320 (Kohler)
Ignition
Throttle Solenoid TS1 V10 Relay CR1
(Pull to idle)

Resistance Values
b) Condition − 70°F (21°C); cold
machine (no warm-up)
c) Wiring Connections − Section 12
d) Stop engine before checking
resistance
R1 26.5 ohms
R2 14.2 ohms (Prior to LB078855 −
Robin / Prior to LB098320 −
Kohler)
18 ohms (Eff w/LB078855 − Robin
/ Eff w/LB098320 − Kohler)
R3 thru R8 Less than 1 ohm
R3, V5
R4 R5
R2,
V4
I1 V3
R6
R7, V9
Test Equipment Needed:
V2
Amperage Readings
machine (no warm-up); no load
R8 I1 0.9 amps dc
See Section 10-3

V1, A, B for waveforms
A, B,
V15
V14
V13 222 129−A / Ref. 230 514-A (Kohler Engine)

10-3. Waveforms For Section 10-2
The waveforms represent the output
of the welding power source. When
operating properly, the power source
waveforms match those shown here.
5 ms 50 V 5 ms 20 V
gnd gnd
A. DC/CC Mode, DC Open-Circuit Voltage, B. DC/CC Output, 25 Volts DC, 175 Amperes,
Amperage Control R1 At Maximum (Resistive Load)

10-4. Field Current Control Board PC1 Testing Information Prior To LA330495 (Onan)
And LA330472 (Kohler)
Be sure plugs are secure before test-
ing. Use Section 10-5 for specific val-
ues during testing.
PC1 test points TP1 and TP4

provide a convenient place to
check essential board voltages
(see Section 10-5)
LED1 lights and weld and gener-

ator power output stops if the unit
is overloaded. Reduce load, turn
unit off, and restart to reset the
generator protection circuit and
resume operation.
1 Field Current Control Board
PC1
2 LED1
3 Test Plug TP1
4 Test Plug TP4
5 Plug PLG5
6 Receptacle RC6
7 Lead 24
8 Lead 23
9 Lead 33
1 4
3
2
7 8 9
802 502 / 197 692

10-5. Field Current Control Board PC1 Test Point Values Prior To LA330495 (Onan) And
LA330472 (Kohler)
a) Tolerance − ±10% unless
specified
machine (no warm-up); no
load; weld/power rpm unless
PC1 Voltage Readings noted
c) Reference − to circuit common
(TP4 pin 10) unless noted
Plug/ Pin Value

Receptacle
TP1 1 Voltage regulator; 1.9 volts ac
(Test Point)
2 Voltage feedback input; +6.3 volts dc
3 Engine rpm voltage output; +6.2 volts dc
4 Engine rpm voltage input; 0.5 volts ac
5 +10 volts dc
6 Field current regulator; −9.9 volts dc
7 Current regulator; +3.9 volts dc
8 Gate drive; +0.8 volts dc
TP4 1 Current feedback input; 0 volts dc at no load; +1 volt dc per 40 amperes weld output
(Test Point)
2 Not used
3 Not used
4 Not used
5 Circuit common
6 Slope; + 3 volts dc
7 Idle circuit feedback input; 0 volts ac at no load
8 Reduction output; idle rpm:+0.8 volts dc to −7 volts dc output from min to max of Amperage control
R1, weld/power rpm:+ 0.8 volts dc
9 Not used
10 Circuit common
11 −15 volts dc input
12 +15 volts dc input
RC5 1 +11.7 volts dc output at idle rpm; 0 volts dc at weld/power rpm
2 +13.8 volts dc with Engine Control switch S2 in Run/Idle position
3 +12 volts dc
4 +190 volts dc
5 +175 volts dc
6 Circuit common
7 235 volts ac with respect to PLG5-8
8 235 volts ac with respect to PLG5-7
9 +12 volts dc
RC6 1 0 volts dc
2 Circuit common
3 +190 volts dc
4 Same as weld terminal OCV;+73 volts dc max with respect to RC6-5
5 Same as weld terminal OCV;+73 volts dc max with respect to RC6-4
6 Circuit common
7 +15 volts dc

Plug/ Pin Value
Receptacle
8 −15 volts dc
9 0 volts dc at no load; +1 volt dc per 50 amperes weld output
Lead 23 − 0 to +10 volts dc input from min to max of Amperage control R1
Lead 24 − +10 volts dc output
Lead 33 − Circuit common
10-6. Field Current Control Board PC1 Testing Information Eff w/LA330495 Thru
LB171606 (Onan) And Eff w/LA330472 Thru LB163304 (Kohler)
ues during testing.

(see Section 10-7)

resume operation.
PC1
2 LED1
3 Test Plug TP1
4 Test Plug TP4
1 3 4 5 Plug PLG5
6 Receptacle RC6
7 Receptacle RC1
7
6
802 502-A / 201 028

10-7. Field Current Control Board PC1 Test Point Values Eff w/LA330495 Thru LB171606
(Onan) And Eff w/LA330472 Thru LB163304 (Kohler)
specified
Plug/ Pin Value
Receptacle
(Test Point)
5 +10 volts dc
(Test Point)
2 Not used
3 Not used
4 Not used
5 Circuit common
6 Slope; + 3 volts dc
7 Idle circuit feedback input; 0 volts ac at no load
8 Reduction output; idle rpm:+0.8 volts dc to −7 volts dc output from min to max of Amperage control
R1, weld/power rpm:+ 0.8 volts dc
9 Not used
10 Circuit common
11 −15 volts dc input
12 +15 volts dc input
2 +13.8 volts dc with Engine Control switch S2 in Run/Idle position
3 +12 volts dc
4 +190 volts dc
5 +175 volts dc
6 Circuit common
7 Prior to LB078855 (Onan) and LB098320 (Kohler): 235 volts ac with respect to PLG5-8;
Eff w/LB078855 (Onan) and LB098320 (Kohler): 248 volts ac with respect to PLG5-8
8 Prior to LB078855 (Onan) and LB098320 (Kohler): 235 volts ac with respect to PLG5-7
Eff w/LB078855 (Onan) and LB098320 (Kohler): 248 volts ac with respect to PLG5-7
9 +12 volts dc
RC6 1 0 volts dc
2 Circuit common
3 +190 volts dc
4 Same as weld terminal OCV; +73 volts dc with respect to RC6-5

Plug/ Pin Value
Receptacle
6 Circuit common
7 +15 volts dc
8 −15 volts dc
RC1 1 0 to +10 volts dc input from min to max of Amperage control R1
2 +10 volts dc output
3 Circuit common
4 Not used

10-8. Field Current Control Board PC1 Testing Information Eff w/LB171607 (Robin) And
LB163305 (Kohler) And Following
ues during testing.

(see Section 10-9)

resume operation.
PC1
LED Location
802 502−B / 203 656

10-9. Field Current Control Board PC1 Test Point Values Eff w/LB171607 (Robin) And
LB163305 (Kohler) And Following

specified
Plug/ Pin Value

Receptacle
(Test Point)
5 Circuit common
(Test Point)
2 Slope; −1.8 volts dc to + 3 volts dc (varies w/pot. setting)
3 Auxiliary voltage feedback; 6.2 volts dc
4 Slope cut-in; 0 to −15 volts dc (varies w/pot. setting)
RC1 1 0 to +10 volts dc input from min to max of Amperage control R1
2 +10 volts dc output
3 Circuit common
RC2 1 +15 volts dc
2 Circuit common
3 Circuit common
5 −15 volts dc
6 +190 volts dc
7 +73 volts dc with respect to RC2-4
8 0 volts dc at no load
2 +12 volts dc with Engine Control switch S2 in Run/Idle position
3 +190 volts dc
4 +13.8 volts dc output with engine running
5 +12 volts dc
6 +175 volts dc
RC4 1 Circuit common
2 248 volts ac with respect to RC4-3
3 248 volts ac with respect to RC4-2

10-10. Replacing Brushes And Cleaning Slip Rings
1 Endbell
2 Brushes
3 Brush Holder Assembly
Remove brush holder assembly.
Keep hardware for reinstallation.
Do not remove brushes from hol-
der. Replace brush holder assem-
bly if brushes are damaged, or at or
near minimum length.
4 Slip Rings
Visually inspect slip rings. Under
normal use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine and clean rings with a
commutator stone. Remove as little
material as possible.
Stop engine.
Install brush holder assembly and
remaining generator parts (see
Section 11-2 for torque values).
Reinstall side panels and cover.
Tools Needed:
3/8 in
1
2
1/4 in (6.4 mm)

Minimum Length
1/2 in (12.7 mm)

New Length
Replace
Damaged Brushes
802 502-B / Ref. 801 521-C / Ref. S-0233-A

10-11. Checking Unit Output After Servicing
Also use output waveforms to

check unit output after servic-
ing (see Section 10-3).
Check engine speeds, and adjust if
necessary (see Section 7-7 or 8-7).
1 120 Volt AC Receptacles RC2
And RC3
2 240 Volt AC Receptacle RC1
Check voltage at receptacles. With
no load applied, there should be 115
− 120 volts ac present at RC2 and
1 RC3, and 230 − 240 volts present at
RC1.
3 Weld Output Terminals
Check open-circuit voltages
between terminals according to
Section 10-2 (voltage V1).
If correct voltage is not present,
repeat troubleshooting procedures
in Section 10-1.
Complete pre-operational checks
in table. Reinstall cover and side
panels.
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 4-2 or 4-3).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Tools Needed:
3/8 in
Ref. 802 502-B

SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly/Reassembly Of Unit
An Onan-powered unit is
shown.
Disassembly
Use Section 10-1 to determine if
trouble is in rotor, stator, engine or
a combination of these
components.
Do not damage rotor or
stator windings.
Disconnect battery cables, fuel line,
choke cable, and base ground
cable. Remove spark plugs.
Mark and disconnect leads from
front panel components. Mark and
disconnect stator leads.
Disassemble in sequence shown.
1 Rotor Removal Spacer (Miller
Part No. 177 126)
2 Rotor Removal Tool (Miller
Part No. 147 551)
3 8 x 1.25 x 40 mm Screw
Install tool and spacer on flywheel.
Loosen rotor before removing engi-
ne/generator assembly. Remove
3 tool from flywheel after loosening
2 rotor.
1 Use hoist and lifting strap to
carefully remove engine/
generator assembly.
Go to Section 11-2.
Loosen rotor
before removing
engine/generator Tools Needed:
assembly.
802 502-B

11-2. Disassembly/Reassembly Of Generator
Torques:
A 25 in lb (3 N.m)
B 40 ft lb (54 N.m) Apply anti-seize compound
(Loctite 76732) to all con-
C 35 ft lb (47 N.m) tacting surfaces between
rotor and engine.
4
7 6 5
8
C
A
802 345-B
Do not damage rotor or stator blocks, remove hardware securing stator Reassembly
windings. to engine.
Reinstall engine and generator parts using
Do not pound on generator housing 1 O-Ring torque values in table.
during disassembly or housing will 2 Front Generator Housing
Reconnect leads as marked. Use cable ties
be damaged. 3 Generator Fan to keep leads from sharp edges, and hot or
4 Rear Generator Housing
Remove brush assembly before
5 Rotor
moving parts.
removing generator housing. Reconnect fuel line, choke cable, and base
6 Slip Rings ground cable Reinstall spark plugs, battery
Disassembly 7 Bearing and tray, panels, and cover. Reconnect
With engine properly supported with 8 Brush Holder Assembly battery cables.

SECTION 12 − ELECTRICAL DIAGRAMS
The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Circuit Wiring
Model Serial Or Style Number
Diagram Diagram
Champion 10,000 KK254680 thru LA330494 196 661

(Onan-Powered)
LA330495 thru LB098425 201 489
Champion 10,000 KK254680 thru LA330471 196 663

(Kohler-Powered)
LA330472 thru LB104240 201 488
Champion 10,000 LB098426 thru LB171606 (Onan) 202 073

(Robin [Onan] and Kohler-Pow- LB104241 thru LB163304 (Kohler)
ered)
LB171607thru LE385381 (Onan) 204 710

LB163305 thru LE385381 (Kohler)
LE385382 thru LG210240H 222 129
LG210241H and following 230 514-A See Table 12-1 (Robin)

See Table 12-2 (Kohler)
Circuit Board PC1 KK254680 thru LA330494 (Onan) 197 693-A

KK254680 thru LA330471 (Kohler)
LA330495 thru LB171606 (Onan) 201 029

LA330472 thru LB163304 (Kohler)
LB171607 and following (Robin) 203 657

LB163305 and following (Kohler)

196 661
Figure 12-1. Circuit Diagram For Welding Generator (Onan-Powered Units)

Effective With Serial No. KK254680 Thru LA330494
201 489
Figure 12-2. Circuit Diagram For Welding Generator (Onan-Powered Units)

Effective With Serial No. LA330495 Thru LB098425
196 663
Figure 12-3. Circuit Diagram For Welding Generator (Kohler-Powered Units)

Effective With Serial No. KK254680 Thru LA330471
201 488
Figure 12-4. Circuit Diagram For Welding Generator (Kohler-Powered Units)

Effective With Serial No. LA330472 Thru LB104240
202 073
Figure 12-5. Circuit Diagram For Welding Generator

Eff w/ Serial No. LB098426 Thru LB171606 (Onan) And LB104241 Thru LB163304 (Kohler)
204 710
Figure 12-6. Circuit Diagram For Welding Generator

Eff w/ Serial No. LB171607 (Onan) And LB163305 (Kohler) Thru LE385381
222129−A
Figure 12-7. Circuit Diagram For For Welding Generator

Eff w/ Serial No. LE385382 Thru LG210240H
230 514-A
Figure 12-8. Circuit Diagram For Welding Generator Eff w/LG210241H

Notes

Figure 12-9. Circuit Diagram For Control Board PC1 Eff w/ Serial No. KK254680 Thru LA330494 (Onan)
And KK254680 Thru LA330471 (Kohler) (1 Of 2)
197 693-A

Figure 12-10. Circuit Diagram For Control Board PC1 Eff w/ Serial No. KK254680 Thru LA330494 (Onan)
And KK254680 Thru LA330471 (Kohler) (2 Of 2)
Notes
Over 80,000 trained
Figure 12-11. Circuit Diagram For Control Board PC1 Effective With Serial No.
LA330495 Thru LB171606 (Onan) And LA330472 Thru LB163304 (Kohler) (1 Of 2)
201 029

201 029
LA330495 Thru LB171606 (Onan) And LA330472 Thru LB163304 (Kohler) (2 Of 2)
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

LB171607 And Following (Onan) And LB163305 And Following (Kohler) (1 Of 2)
203 657

203 657
LB171607 And Following (Onan) And LB163305 And Following (Kohler) (2 Of 2)
Table 12-1. Lead List Summary For Champion 10,000 Eff w/LE385382 And Following (Onan)
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 (Part No. 146 557) to connectors where factory-applied grease
had been present.
Lead Connections Lead Connections

1A . . . . . . RC4 (1) TO PLG8 61B . . . . . CB2 TO CB1
2A . . . . . . RC4 (2) TO PLG5 (1) 62A . . . . . RC1 (X) TO CB1
5A . . . . . . RC4 (5) TO PLG8 62B . . . . . CB3 TO CB1
6A . . . . . . RC4 (6) TO PLG8 63A . . . . . RC2 (Y) TO CB2
7A . . . . . . PLG8 TO PLG5 (4) 64A . . . . . RC3 (Y) TO CB3
20B . . . . . RC4 (3) TO PLG5 (5) 70A . . . . . STATOR THRU CT1 TO SR1 (AC)
20D . . . . . HR MTR (+) TO PLG5 (2) 71A . . . . . STATOR TO SR1 (AC)
21B . . . . . PLG5 (3) TO BRUSH (FRONT) 72A . . . . . EDGEWOUND TO SR1 (+)
21C . . . . . PLUG 6 (6) TO SR2 (+) 72B . . . . . PLUG 6 (7) TO SR1 (+)
22A . . . . . SR2 (AC) TO CB5 73A . . . . . DC−Z START TO WELD STUD (+)
23 . . . . . . R1 (CENTER) TO PLG7 (1) 74A . . . . . SR1 (−) TO WELD STUD (−)
24 . . . . . . R1 (CW) TO PLG7 (2) 74B . . . . . PLUG 6 (4) TO SR1 (−)
26B . . . . . PLG5 (6) TO BRUSH (REAR) 82A . . . . . DC−Z FINISH TO EDGE WOUND COIL
28A . . . . . STATOR TO F1
29A . . . . . STATOR TO SR2 (AC)
33A . . . . . RC2 (GR) TO GROUND STUD
33B . . . . . RC3 (GR) TO GROUND STUD
33B . . . . . R1 (CCW) TO PLG7 (3)
33C . . . . . RC1 (GR) TO GROUND STUD
33H . . . . . 1T (A) TO RC4 (4)
33J . . . . . SR2 (−) TO 1T (B)
33K . . . . . 1T (B) TO PLG9 (1)
33M . . . . . 1T (A) TO HR MTR (−)
33N . . . . . 1T−D TO FRAME GROUND #2
33P . . . . . GROUND STUD TO FRAME GROUND #2
50A . . . . . STATOR TO 1T−E
51A . . . . . STATOR TO 1T−F
51D . . . . . 1T (F) TO PLG9 (3)
52A . . . . . STATOR TO 1T−D
53A . . . . . STATOR TO 1T−C
53D . . . . . 1T (C) TO PLG9 (2)
60A . . . . . RC2 (W) TO RC3 (W)
60B . . . . . RC2 (W) TO 1T−E
60C . . . . . RC1 (W) TO 1T−D
61A . . . . . RC1 (Y) TO CB1

Table 12-2. Lead List Summary For Champion 10,000 Eff w/LG210241H And Following (Kohler)
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 (Part No. 146 557) to connectors where factory-applied grease
had been present.
Lead Connections Lead Connections

1A . . . . . . RC4 (1) TO PLG8 33M . . . . . 1T (A) TO HR MTR (−)
1C . . . . . . PLG10 (1) TO RC10 (1) 33N . . . . . 1T−D TO FRAME GROUND #2
2A . . . . . . RC4 (2) TO PLG5 (1) 33P . . . . . GROUND STUD TO FRAME GROUND #2
2C . . . . . . PLG10 (2) TO RC10 (2) 50A . . . . . STATOR TO 1T−E
3C . . . . . . PLG10 (3) TO RC10 (3) 51A . . . . . STATOR TO 1T−F
4C . . . . . . PLG10 (4) TO ENG GND 51D . . . . . 1T (F) TO PLG9 (3)
5A . . . . . . RC4 (5) TO PLG8 52A . . . . . STATOR TO 1T−D
5C . . . . . . PLG10 (5) TO RC10 (5) 53A . . . . . STATOR TO 1T−C
6A . . . . . . RC4 (6) TO PLG8 53D . . . . . 1T (C) TO PLG9 (2)
6C . . . . . . PLG10 (6) TO RC10 (6) 60A . . . . . RC2 (W) TO RC3 (W)
7A . . . . . . PLG8 TO PLG5 (4)
60B . . . . . RC2 (W) TO 1T−E
20B . . . . . RC4 (3) TO PLG5 (5)
60C . . . . . RC1 (W) TO 1T−D
20D . . . . . HR MTR (+) TO PLG5 (2)
61A . . . . . RC1 (Y) TO CB1
21B . . . . . PLG5 (3) TO BRUSH (FRONT)
61B . . . . . CB2 TO CB1
21C . . . . . PLUG 6 (6) TO SR2 (+)
62A . . . . . RC1 (X) TO CB1
22A . . . . . SR2 (AC) TO CB5
62B . . . . . CB3 TO CB1
23 . . . . . . R1 (CENTER) TO PLG7 (1)
63A . . . . . RC2 (Y) TO CB2
24 . . . . . . R1 (CW) TO PLG7 (2)
26B . . . . . PLG5 (6) TO BRUSH (REAR) 64A . . . . . RC3 (Y) TO CB3
28A . . . . . STATOR TO F1 70A . . . . . STATOR THRU CT1 TO SR1 (AC)
29A . . . . . STATOR TO SR2 (AC) 71A . . . . . STATOR TO SR1 (AC)
33A . . . . . RC2 (GR) TO GROUND STUD 72A . . . . . EDGEWOUND TO SR1 (+)
33B . . . . . RC3 (GR) TO GROUND STUD 72B . . . . . PLUG 6 (7) TO SR1 (+)
33B . . . . . R1 (CCW) TO PLG7 (3) 73A . . . . . DC−Z START TO WELD STUD (+)
33C . . . . . RC1 (GR) TO GROUND STUD 74A . . . . . SR1 (−) TO WELD STUD (−)
33H . . . . . 1T (A) TO RC4 (4) 74B . . . . . PLUG 6 (4) TO SR1 (−)
33J . . . . . SR2 (−) TO 1T (B) 82A . . . . . DC−Z FINISH TO EDGE WOUND COIL
33K . . . . . 1T (B) TO PLG9 (1)

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/KK254680 Thru LA199099

For OM-945 (194 047) Revisions A And B
SECTION 13 − PARTS LIST FOR KK254680 THRU LA199099
Hardware is common and
not available unless listed.
Kohler
8 only 9
7
6
10
4
11
3
2
1
13
12
14
47
17
49 − Fig 13-2
15
19
16
46 18
48
20 − Fig 13-3
19
21
45
44 22
43 23
42
41
25 24
40 26
39
36 27
33 37 18
38
17
28
35
34
29
30
31
32
802 343-B
Figure 13-1. Main Assembly (Onan Engine Shown)

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 13-1. Main Assembly
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . 184 791 . . Label, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 2 . . . . . . . . . . . . . . . . . 182 761 . . Label, Warning Gen. Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 192 042 . . Label, Use Gasoline Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . . . . 181 881 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . . . . 147 601 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . . . . 108 487 . . Label, Warning:Falling Equipment Can Cause Serious . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . . . . 183 433 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . . . . 196 252 . . Baffle, engine air (Kohler only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . . . 194 263 . . Grommet, Plastic Snap−in Battery Access . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 168 385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 183 314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . . . 195 845 . . Engine, Onan Gas Elec Start (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 193 845 . . . . Muffler, Exhaust Engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 755 . . . . Element, air cleaner w/precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . . . 198 757 . . . . Switch, low oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *121 652 . . . . Filter, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid w/ mtg bracket (see engine parts list) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 778 . . . . Regulator, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . . . 165 271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . . . . *021 718 . . . . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . . . 194 249 . . Engine, Kohler Gas Elec Ch20s−ps−64635 (consisting of) . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 193 856 . . . . Muffler, Exhaust Engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 272 . . . . Element, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *067 273 . . . . Wrapper, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 180 096 . . Kit, tune-up and filter − Kohler (includes air filter element and wrapper,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil filter, fuel filter, and spark plugs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . . . 196 778 . . Hose, Vinyl Clear .500 Id X .625 Od X 7.000 (oil drain) . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 167 788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 151 542 . . Washer, Flat .438idx1.000odx.125t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . 3
. . 19 . . . . . . . . . . . . . . . . 142 156 . . Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . 3
. . 20 . . . . . . . . . . . . . Figure 13-3 . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . . . 082 319 . . Cable, Bat Neg 17.750 No 4 Awg W/Clamp & .343 Rng . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . . . . . 168 037 . . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Dry . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . . . 173 921 . . Cable, Bat Pos 28.000 No 4 Awg W/Clamp & .312 Rng . . . . . . . . . . . 1
. . 25 . . . . . . . . . . . . . . . . 172 669 . . Cable, Bat Neg 11.000 6ga W/.250 Rng & .375 Rng . . . . . . . . . . . . . . 1
. . 26 . . . . . . . . . . . . . . . . 182 935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . . . . . . . . . . . . . 193 780 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +193 783 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 194 074 . . Label, Engine Maintenance Onan/Robin Eh63 . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 173 088 . . Label, Engine Maintenance Kohler Ch18/Ch20 . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . . . . . . . . . . . . . . 197 930 . . Label, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . 32 . . . . DC-Z . . . . . . 193 922 . . Stabilizer Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 33 . . . . . . . . . . . . . . . . 193 987 . . Rectifier, W/Components (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . SR1 . . . . . . 197 514 . . . . Rectifier, Si 1ph 280 Amp 400 Piv 60% Duty Cycle . . . . . . . . . . . . . 1
. . 35 . . . . LEM . . . . . . 191 941 . . . . Transducer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG6, PLG7 . . 194 065 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . SR2 . . . . . . 035 704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . F1 . . . . . . . . 011 116 . . . . Fuse, Mintr Gl Slo−blo 7 Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . . . . . 172 731 . . . . Holder, Fuse Mintr .250 X 1.250 Clip Anti−pivot . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . . . 193 781 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . . . . . 193 627 . . Tank, Fuel 10 Gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . 178 632 . . Ftg, Stand Pipe .250 X 7.375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . . . . . 124 253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . . . . . 066 113 . . Filter, Fuel Inline .250 (included w/engine) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 45 . . . . . . . . . . . . . . . . 084 173 . . Clamp, Hose .460 − .545 Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 46 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 47 . . . . . . . . . . . . . . . . 160 975 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . . . . . . 180 628 . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 49 . . . . . . . . . . . . . Figure 13-2 . . Panel, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 193 067 . . Kit, Accy 20 Ft (#2) W/Elec Hldr 15 Ft Grd (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 600 319 . . . . Cable, Weld Cop Strd No 2 Epdm Jkt (order by ft) . . . . . . . . . . . . . . 35ft
. . . . . . . . . . . . . . . . . . . . . . 040 234 . . . . Af−2 Holder, Electrode 200a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 600 720 . . . . Term, Ring Tng 500stud Solistrand 2ga . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
1 2 3 4 5
24
6
23 7
22 8
21 9
25
16
19 17
12
18 13
26 10
20
14
11
15
802 344-B
Figure 13-2. Panel, Front w/Components

Item Dia. Part
Figure 13-2. Panel, Front w/Components (Figure 13-1 Item 49)

. . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (order by model & serial no.) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . . . . 194 004 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 165 316 . . STAND−OFF, no 6−32 x .875 lg .312 hex nyl .156
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LA037188) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 3 . . . . . . . . . . . . . . . . . 144 844 . . STAND−OFF, no 6−32 x .875 lg .250 hex al fem (Eff w/LA037188) . . 4
. . 4 . . . . . PC1 . . . . . . 201 279 . . Circuit Card Assy, Field Current Controller (Service Kit − Includes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Potentiometer R1 - Part No. 201 486) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . CT1 . . . . . . 193 929 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 176 606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 193 927 . . Harness, Wrg Ignition (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . . . 177 859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . . 116 045 . . . . Conn, Rect Univ 084 6p/S 3row Rcpt (Housing, Pins & Skts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . RC2, RC3 . . . . 141 432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . GFCI2, GFCI3 . ♦151 981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r GFI . . . . . . . . . . . . . . . . . . 2
. . 8 . . . CB1, CB2 . . . . 195 955 . . Circuit Breaker, Man Reset 1p 50a 125vac Screw−90 . . . . . . . . . . . . . 2
. . 9 . . . CB3, CB4 . . . . 093 996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . . . . . 203 993 . . Control, Push/Pull Snap−in 36.000 W/1.750 Extension . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 119 014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . . . . . 1T . . . . . . . 172 661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . POS . . . . . . 039 047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . NEG . . . . . . 039 046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . WASHER, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 19 . . . . RC1 . . . . . . 182 954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . . . 188 039 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . . . 097 924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . . . . . 072 590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . HM . . . . . . . 145 247 . . Meter, Hour 12−24vdc 1.25 X 2.12 Rect . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . . . . . . . . . . . . 602 207 . . Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . 1
. . 26 . . . . . . . . . . . . . . . . 163 167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . 1
♦Optional

Item Part
No. No. Description Quantity
Figure 13-3. Generator (Figure 13-1 Item 20)
. . 1 . . . . . . . . . . . . . . . . +208 973 . . Housing, Generator Front w/Stator (consisting of) . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 183 419 . . . . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, Weld/Pwr Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . . . . 195 956 . . Screw, 250−20x5.75 Hexwhd.50d Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 5 . . . . . . . . . . . . . . . . . 185 148 . . Housing, Generator Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . . . . 186 083 . . Screw, 437−14x1.75 Hexwhd.93d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . 4
. . 7 . . . . . . . . . . . . . . . . . 193 725 . . Rotor, Generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 181 143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .59 . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . . . 180 556 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 013 367 . . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . 1
3 6
1 8
2 9
7
10
11
12
802 345-A
Figure 13-3. Generator

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/LA199100 Thru LB098425 (Onan)

And LA199100 Thru LB104240 (Kohler)
For OM-945 (194 047) Revisions C Thru G
SECTION 14 − PARTS LIST FOR LA199100 THRU
LB098425 (ONAN) AND LA199100 THRU LB104240 (KOHLER)
Hardware is common and Kohler
not available unless listed. 8 only 9
7
6
10
5 48
4
11
3
1
13
12
14
45
17
47 − Fig 14-2
15
19
16
44 18
46
20 − Fig 14-3 or
19
21 Fig 14-4
43
42 22
41 23
40
39
25 24
38 26
37
36 27
33 18
17
28
35
34
29
30
31
802 343-D
32

Eff w/LA199100 Thru LB098425 (Onan) And LA199100 Thru LB104240 (Kohler)
Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 184 791 . . Label, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 6 . . . . . . . . . . . . . . . . . 200 795 . . Label, Warning General Precautionary Csa
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LB034097−Onan; Eff w/LB033947−Kohler) . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . Figure 14-3 or Figure 14-4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +193 783 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Item Dia. Part

. . . . . . . PLG6, PLG7 . . 194 065 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . . . . . . 108 487 . . Label, Warning Falling Equipment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LB034097−Onan; Prior to LB033947−Kohler) . . . . . . . . . . . . . 1
1 2 3 4
28
5
26
6
25 7
24 8
21 9
23
22
29
27
16
19 17
12
18 13
30 10
20
14
11
15
802 344-E

Item Dia. Part

. . 2 . . . . . . . . . . . . . . . . . 194 004 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 144 844 . . Stand-off, no 6−32 x .875 lg .250 hex al fem . . . . . . . . . . . . . . . . . . . . . . 4
. . 4 . . . . . PC1 . . . . . . 201 279 . . Circuit Card Assy, Field Current Controller (Service Kit)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LA330495−Onan; Prior to LA330472−Kohler) . . . . . . . . . . . . . 1
. . 4 . . . . . PC1 . . . . . . 201 027 . . Circuit Card Assy, Field Current Controller (Eff w/LA330495 thru
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LB078854−Onan; Eff w/LA330472 thru LB098319−Kohler) . . . . . . . . . 1
. . 4 . . . . . PC1 . . . . . . 203 790 . . Circuit Card Assy, Field Current Controller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . CB1, CB2 . . . . 195 955 . . Circuit Breaker, Man Reset 1p 50a 125vac Screw−90 . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . Washer, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . F1 . . . . . . . 027 660 . . Fuse, mintr cer 20 Amp, 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . . . . . 200 422 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . . . . . . . . . . . . . 200 532 . . Label, warning CSA circuit breaker
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LA274850−Onan; Eff w/LA258062−Kohler) . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . R1 . . . . . . . 201 486 . . Potentiometer, w/leads
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LA330472−Onan); Eff w/LA330495−Kohler) . . . . . . . . . . . . . . . . 1
♦Optional

Item Part
Figure 14-3. Generator (Prior To LB078055−Onan; Prior To LB098320−Kohler)
(Figure 14-1 Item 20)
. . 1 . . . . . . . . . . . . . . . . +208 973 . . Housing, Generator Front w/Stator (consisting of) . . . . . . . . . . . . . . . . . 1

. . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, Weld/Pwr Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . . . . 195 956 . . Screw, 250−20x5.75 Hexwhd.50d Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 8 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . . . 180 556 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 013 367 . . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . 1
3
6
1 8
2 9
7
10
11
12
802 345-A
Figure 14-3. Generator (Prior To LB078055−Onan; Prior To LB098320−Kohler)

Item Part
Figure 14-4. Generator (Eff w/LB078055−Onan; Eff w/LB098320−Kohler)
(Figure 14-1 Item 20)
. . 1 . . . . . . . . . . . . . . . . +203 925 . . Generator Assy, Front (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . 195 956 . . . . Screw, 250−20x5.75 Hexwhd.50d Stl Pld . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 188 447 . . . . Washer, flat .281idx0.500odx.061t stl pld . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 202 984 . . . . Washer, belleville .500 od x .255 id x .038 thk . . . . . . . . . . . . . . . . . . 4
. . 3 . . . . . . . . . . . . . . . . . 013 367 . . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 205 725 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 7
8
6
10 802 345-B
Figure 14-4. Generator (Eff w/LB078055−Onan; Eff w/LB098320−Kohler)

Notes

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/LB098426 Thru LC089660 (Onan)

Eff w/LB104241 Thru LC089660 (Kohler)
For OM-945 (194 047) Revisions H Thru J
SECTION 15 − PARTS LIST FOR LB098426 THRU
LC089660 (ONAN) AND LB104241 THRU LC089660 (KOHLER)

not available unless listed. Kohler
8 only 9
7
6
10
4
11
3
1
13
12
14
45
17
47 − Fig 15-2
15
19
16
44 18
46
20 − Fig 15-3
19
21
43
42 22
41 23
40
39
25 24
38 26
37
36 27
33 18
17
28
35
34
29
30
31
32 802 343-D

Eff w/LB098426 Thru LC089660 (Onan) And LB104241 Thru LC089660 (Kohler)
Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 184 791 . . Label, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 6 . . . . . . . . . . . . . . . . . 200 795 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +193 783 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Item Dia. Part
. . 33 . . . . . . . . . . . . . . . . 193 987 . . Rectifier, W/Components (Prior to LB171607−Onan;
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to LB163305−Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG6, PLG7 . . 194 065 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . . . . . 204 704 . . Rectifier, W/Components (Eff w/LB171607−Onan;
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eff w/LB163305−Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG6, PLG7 . . 204 705 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 3 4
1 5
26
6
25
8
24
7
21 23
22
9
29 30
16
28
19 17
12
18 13
31 10
20 14
11
15
802 344-E

Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . . 198 122 . . Stand−off Support, Pc Card .250w/Post&lock .500 . . . . . . . . . . . . . . . . 6

. . 3 . . . . . . . . . . . . . . . . . 202 068 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . CT1 . . . . . . 202 665 . . Xfmr, Current Sensing
. . 5 . . . . . CT1 . . . . . . 204 709 . . Xfmr, Current Sensing
. . . . . . . . . . . . . . . . . . . . . . 193 927 . . Harness, Wrg Ignition (Prior to LB171607−Onan;
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to LB163305−Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 204 707 . . Harness, Wrg Ignition (Eff w/LB171607−Onan;
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eff w/LB163305−Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . . . 092 670 . . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg (Housing, Pins &
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skts Service Kit)
. . 8 . . . . . CB1 . . . . . . 221 515 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . Washer, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . . R1 . . . . . . . 201 486 . . Potentiometer, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . . 202 631 . . Cover, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 202 630 . . Brkt, Mtg Ckt Breaker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

Item Part

. . 7 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 7
8
6
10 802 345-B

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/LC089661 Thru LC654121

(Onan & Kohler)
For OM-945 (194 047) Revisions K Thru Q
SECTION 16 − PARTS LIST FOR LC089661 THRU LC654121
(ONAN & KOHLER)

not available unless listed. Kohler
8 only 9
7
6
10
4
11
3
1
13
12
14
45
17
47 − Fig 16-2
15
19
16
44 18
46
20 − Fig 16-3
19
21
43
42 22
41 23
40
39
25 24
38 26
37
36 27
33 18
48
17
28
35
34
29
30
31
32
802 343-D

Eff w/LC089661 Thru LC654121 (Onan & Kohler)
Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 184 791 . . Label, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 827 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +193 783 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Eff w/LC089661 Thru LC654121(Onan & Kohler)
Item Dia. Part
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . PLG6, PLG7 . . 204 705 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . . . 178 632 .. Ftg, Stand Pipe .250 X 7.375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 47 . . . . . . . . . . . . . Figure 16-2 . . Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . . . . . . 208 149 . . Bracket, Mtg. Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 4
2
1 5
26
6
25
8
24
7
21 23
22
9
29 30
16
28
19 17
12
18 13
31
10
20 14
11
15
802 344-E

Eff w/LC089661 Thru LC654121 (Onan & Kohler)
Item Dia. Part

. . 3 . . . . . . . . . . . . . . . . . 202 068 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . PC1 . . . . . . 203 655 . . Circuit Card Assy, Field Current Controller . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 176 606 . . Switch, Ignition 4 Position W/Out Handle (Prior to LC503067) . . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 207 110 . . Switch, Ignition 4 Position W/Out Handle (Eff w/LC503068) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skts Service Kit)
. . 8 . . . . . CB1 . . . . . . 221 515 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 119 014 . . Lever, Switch Black (Prior to LC503067) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 207 073 . . Lever, Ignition Switch (Eff w/LC503068) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . Washer, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . . . 097 924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screwsplstc (Prior to LC503067) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . . . 207 077 . . Knob, Pointer 1.625 Dia Push On (Eff w/LC503068) . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 202 630 . . Brkt,Mtg Ckt Breaker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

Eff w/LC089661 Thru LC654121(Onan & Kohler)
Item Part

. . 7 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 7
8
6
10 802 345-B

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/LC654122 Thru LE385381

(Robin & Kohler)
For OM-945 (194 047) Revisions Q Thru U
SECTION 17 − PARTS LIST EFF W/LC654122 THRU
LE385381 (ROBIN & KOHLER)
Hardware is common and Kohler

9
not available unless listed. 8 only
7
6 10
3 11
13
12
14
43
44 − FIG 17-2
17
19
15
42
16
45
18
20 − FIG 17-3 19
41
40 21
22
39
38 23
37
25 24
36 26
35
34
33 18
17 27
28
29
30
32
802 343−L
31
Figure 17-1. Main Assembly (Robin Engine Shown)
TM−945 Page 100 Champion 10,000

Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 184 791 . . Label, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 5 . . . . . . . . . . . . . . . . . 147 601 . . Cap, Tank Screw−on w/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . . . 195 845 . . Engine, Robin (Onan) Gas Elec Start (consisting of) . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 193 845 . . . . Muffler, Exhaust Engine (Robin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 114 923 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 199 062 . . Kit, tune-up and filter − Robin (Onan) (includes air filter element
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and wrapper, oil filter, fuel filter, and spark plugs) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 923 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +193 783 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 215 939 . . Label, Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Champion 10,000 TM−945 Page 101
Item Dia. Part
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 33 . . . . . . . . . . . . . . . . 204 704 . . Rectifier, W/Components (consisting of) (Prior to LE385381) . . . . . . . 1
. . . . . . . PLG6, PLG7 . . 204 705 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . SR1 . . . . . . 220 782 . . Rectifier, Si 1ph 400 Amp 400 Piv 60% Duty Cycle (Eff w/LE385382) 1
. . 37 . . . . . . . . . . . . . . . . 178 632 . . . . Ftg, Stand Pipe .250 X 7.375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23
3
1 2 4
5
33
32
27
8
26
25 6
24
7
21
29 30
28 16
19 17 12
13
18
31 15 10
14
11
20
802 344−J

Item Dia. Part

. . 3 . . . . . . . . . . . . . . . . . 202 068 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 207 110 . . Switch, Ignition 4 Position Without Handle (Prior to LE385381) . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 217 680 . . Switch, Ignition 4 Position Without Handle (Eff w/LE385382) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skts Service Kit)
. . 8 . . . . . CB1 . . . . . . 200 929 . . Circuit Breaker, Man Reset 2p 50a
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240vac Screw−90 (Prior to LE204521) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . CB1 . . . . . . 218 591 . . Circuit Breaker, Man Reset 2p 50a
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240vac Screw−90 (Eff w/LE204522) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 207 073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . Washer, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . CB4 . . . . . . 161 078 . . Circuit Breaker, Man Reset 1p 7a 250vac Fri . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . . . 207 077 . . Knob, Pointer 1.625 Dia Push-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . SR2 . . . . . . 035 704 . . Rectifier, Integ Bridge 40 Amp 800 V (Eff w/LE385382) . . . . . . . . . . . . 1
. . 33 . . . . LEM . . . . . . 191 941 . . Transducer, Current (Eff w/LE385382) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 220 632 . . Harness, Wrg, Feedback (consisting of) (Eff w/LE385382) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 220 629 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 135 134 . . . . Conn,Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
♦Optional
Champion 10,000 TM−945 Page 103

Item Part
.. 1 . . . . . . . . . . . . . . . . +203 925 . . Generator Assy, Front (consisting of) (Prior to LE385381) . . . . . . . . . . 1

.. 1 . . . . . . . . . . . . . . . . +220 832 . . Generator Assy, Front (consisting of) (Eff w/LE385382) . . . . . . . . . . . . 1
.. 2 . . . . . . . . . . . . . . . . . 183 419 . . . . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . 1
.. 3 . . . . . . . . . . . . . . . . . 013 367 . . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . 1
.. 4 . . . . . . . . . . . . . . . . . 185 148 . . Housing, Generator Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 5 . . . . . . . . . . . . . . . . . 186 083 . . Screw, 437−14x1.75 Hexwhd.93d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . 4
.. 6 . . . . . . . . . . . . . . . . . 203 933 . . Rotor, Generator (consisting of) (Prior to LE385381) . . . . . . . . . . . . . . 1
.. 6 . . . . . . . . . . . . . . . . . 222 130 . . Rotor, Generator (consisting of) (Eff w/LE385382) . . . . . . . . . . . . . . . . 1
.. 7 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 8 . . . . . . . . . . . . . . . . . 181 143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .59 . . . . . . . . . . . . . . . . . . . 1
.. 9 . . . . . . . . . . . . . . . . . 205 725 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . . . . . . . . . . . . . . . 142 156 . . Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . 4
2 7
8
6
10 802 345-B

TM-945F 2006−08
Processes
Description
Champion 10,000
™
Eff w/LE385382 And Following

(Robin & Kohler)
For OM-945 (194 047) Revisions U Thru AA
SECTION 18 − PARTS LIST EFF W/LE385382
not available unless listed.
8 Kohler
7 only 9
6
5 10
4
2 11
12
13
14
43
44 − FIG 18-2
17
19
15
42
16
45
18
20 − FIG 18-3
19
41 21
40 22
39
38 23
37
25 24
36 26
35
34
18
33
27
17
28
29
30
32
31
802 343−P
Figure 18-1. Main Assembly (Robin Engine Shown)

Item Dia. Part
. . 1 . . . . . . . . . . . . . . . . +193 777 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . . . 192 042 . . Label, Use Gasoline Only (Eff w/ thru ) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . . . . 219 329 . . Label, Use Gasoline Fuel Only (Eff w/ thru LG140410H) . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . . . . 227 725 . . Label, Use Gasoline Fuel Only (Eff w/LG140410H) . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 181 881 . . Grommet, Plastic Neck Filler Fuel (Eff w/ thru ) . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 211 398 . . Grommet, Plastic Neck Filler Fuel (Eff w/ ) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . . . . 220 711 . . Cap, Tank Screw−on w/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . . . . 200 795 . . Label, Warning General Precautionary CSA (Eff w/ thru LE451370) . 1
. . 5 . . . . . . . . . . . . . . . . . 222 324 . . Label, Warning General Precautionary CSA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LE451370 thru LG140410H) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . . . . 227 726 . . Label, Warning General Precautionary CSA (Eff w/LG140410H) . . . . 1
. . 6 . . . . . . . . . . . . . . . . . 220 457 . . Label, Need Help (Eff w/LF081388) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 193 778 . . Panel, Rear (Prior to LF390009H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . . . . 226 448 . . Panel, Rear (Eff w/ LF390009H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 168 385 . . Label, Warning Battery Explosion Can Blind (Eff thru LF081388) . . . . 1
. . 11 . . . . . . . . . . . . . . . . 219 654 . . Label, Warning Battery Explosion Can Blind
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LF081388 thru LG140410H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . . . 227 913 . . Label, Warning Battery Explosion Can Blind (Eff w/LG140410H) . . . . 1
. . 13 . . . . . . . . . . . . . . . . 195 845 . . Engine, Robin Gas Elec Start (consisting of) (Prior to LF160157) . . . 1
. . 13 . . . . . . . . . . . . . . . . 224 134 . . Engine, Robin Gas Elec Start (consisting of) (Eff w/LF160157) . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 193 845 . . . . Muffler, Exhaust Engine (Prior to LG140446H) . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 228 679 . . . . Muffler, Exhaust Engine (Eff w/ LG140446H) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 065 313 . . . . Gasket, muffler (Prior to LG140446H) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 217 441 . . . . Gasket, muffler (Eff w/ LG140446H) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . *198 754 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 198 756 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . *198 777 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 114 923 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 199 062 . . Kit, tune-up and filter − Robin (includes air filter element and wrapper,
. . 13 . . . . . . . . . . . . . . . . 194 249 . . Engine, Kohler Gas Elec Start (consisting of) (Prior to LG210241H) . 1
. . 13 . . . . . . . . . . . . . . . . 230 512 . . Engine, Kohler Gas Elec Ch20s−ps−64760
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (consisting of) (Eff w/LG210241H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 193 856 . . . . Muffler, Exhaust Engine (Prior to (Prior to LG100059H) . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 228 678 . . . . Muffler, Exhaust Engine (Kohler) (Eff w/ LG100059H) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 189 477 . . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 230 506 . . . . Harness, Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 066 698 . . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 190 248 . . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 067 007 . . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 199 530 . . . . Solenoid, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 923 . . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
. . 21 . . . . . . . . . . . . . . . . 193 782 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . . 193 783 . . Base (Prior to LF390009H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . . . +226 446 . . Base (Eff w/LF390009H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . . . 215 939 . . Label, Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . . . . . . . . . . . . . . 197 930 . . Label, Warning Do Not Weld On Base (Prior to LG140410H) . . . . . . . 2
. . 30 . . . . . . . . . . . . . . . . 229 134 . . Label, warning do not weld on base (Eff w/ LG140410H) . . . . . . . . . . . 2
. . 31 . . . . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 33 . . . . SR1 . . . . . . 220 782 . . Rectifier, Si 1ph 400 Amp 400 Piv 60% Duty Cycle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LE385382 thru LG140480H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . SR1 . . . . . . 192 682 . . Rectifier, Si 1ph 240 Amp 400 Piv 60% Duty Cycle (Eff w/LG140480H)1
. . 37 . . . . . . . . . . . . . . . . 178 632 . . . . Ftg, Stand Pipe .250 X 7.375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . . . 145 976 . . Hose, Sae .250 Id X .500 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . . . . . 193 810 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 130 750 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23
3
2 4
1 5
33 27
32
8
26
6
25
24
7
21
29 30
16
28
19 17 12
13
18
31
10
14
20 11
802 344−K

Item Dia. Part

. . 3 . . . . . . . . . . . . . . . . . 202 068 . . Panel, Front (Prior to LF176924) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 223 161 . . Panel, Front (Eff w/LF176924 thru LF390009H) . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 226 447 . . Panel, Front (Eff w/LF390009H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . S2 . . . . . . . 217 680 . . Switch, Ignition 4 Position Without Handle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 204 707 . . Harness, Wrg Ignition (consisting of) (Prior to LE385382) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 222 133 . . Harness, Wrg Ignition (consisting of) (Eff w/LE385382) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skts Service Kit)
. . 8 . . . . . CB1 . . . . . . 218 591 . . Supplementary Protector, Man Reset 2p 50a 240vac . . . . . . . . . . . . . 1
. . 9 . . . CB2, CB3 . . . . 093 996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . 2
. . 11 . . . . . . . . . . . . . . . . 207 073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 039 047 . . Terminal, Pwr Output Red (Prior to LG140480H) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 039 046 . . Terminal, Pwr Output Black (Prior to LG140480H) . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . 099 255 . . Terminal, Pwr Output Neutral (Eff w/LG140480H) . . . . . . . . . . . . . . . . . 2
Item Dia. Part
Figure 18-2. Panel, Front w/Components (Continued)
. . 15 . . . . . . . . . . . . . . . . . Deleted .................................................................
. . 16 . . . . . . . . . . . . . . . . 083 030 . . Stud, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . . . 010 915 . . Washer, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 18 . . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . . . . Deleted ................................................................ 1
. . 23 . . . . CB4 . . . . . . 161 078 . . Circuit Breaker, Man Reset 1p 7a 250vac Fri . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . . . 207 077 . . Knob, Pointer 1.625 Dia Push-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . . HM . . . . . . . 145 247 . . Meter, Hour 12−24vdc 1.25 X 2.12 Rect (Prior to LF176924) . . . . . . . 1
. . 26 . . . . . HM . . . . . . . 223 164 . . Meter, Hour 12−60vdc 2.00 Dia (Eff w/ LF176924) . . . . . . . . . . . . . . . . 1
. . 32 . . . . SR2 . . . . . . 035 704 . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . LEM . . . . . . 191 941 . . Transducer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 220 632 . . Harness, Wrg, Feedback (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 220 629 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 135 134 . . . . Conn,Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
♦Optional

Item Part
. . 1 . . . . . . . . . . . . . . . . +203 925 . . Generator Assy, Front (consisting of) (Prior to LE385382) . . . . . . . . . . 1

. . 1 . . . . . . . . . . . . . . . . +220 832 . . Generator Assy, Front (consisting of) (Eff w/LE385382) . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . . . . 013 367 . . Label, Warning Moving Parts Can Cause
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serious Etc (Prior to LG140410H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 227 724 . . Label, Warning Moving Parts Can Cause
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serious Etc (Eff w/LG140410H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . . . . 203 933 . . Rotor, Generator (consisting of) (Prior to LE385382) . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . . . . 222 130 . . Rotor, Generator (consisting of) (Eff w/LE385382) . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . . . . 181 134 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 7
8
6
10 802 345-B

Hobart Welding Products
An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA
For Technical Assistance:
Call1-800-332-3281
For Literature Or Nearest Dealer:
Call 1-877-Hobart1
PRINTED IN USA © 2006 Hobart Welding Products

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TM-945F 2006−08

Eff. w/Serial Number KK254680

Engine Driven Welding Generator

Note Generator excitation circuit protection change:

Champion 10,000 TM-945

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.

MOVING PARTS can cause injury.

Champion 10,000 TM-945 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

Stop Engine Fast Fast/Slow Slow (Idle)

Start Engine Read Operator’s

Engine Oil Fuel Battery (Engine) Engine

Engine Choke Check Valve Circuit Protector Temperature

Positive Negative Alternating Current Output

Welding Arc Stick (SMAW) Fuse

Champion 10,000 TM-945 Page 3

Height 33-1/2 in (851 mm)

C 23/32 in (18 mm)

E 31-1/2 in (800 mm) F E

G 13/32 in (10 mm) Dia. 25° 25°

Kohler-Powered Unit: 444 lb (201 kg)

Lifting Eye Weight Rating

3-3. Generator Power Curve

TM-945 Page 4 Champion 10,000

3-5. Duty Cycle

6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting

Champion 10,000 TM-945 Page 5

24 Gauge (.025 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)

TM-945 Page 6 Champion 10,000

Do not weld on base. Welding

Do not use flexible mounts. 1

Electrically bond generator frame to

Champion 10,000 TM-945 Page 7

Use correct grade oil for cold weather.

4-3. Engine Prestart Checks (Kohler-Powered Units)

Use correct grade oil for cold weather.

TM-945 Page 8 Champion 10,000

drybatt1 6/05 − S-0886

4-5. Connecting the Battery

Connect negative (−)

Champion 10,000 TM-945 Page 9

4-7. Weld Output Terminals

802 353-G / Ref. 226 427-A

TM-945 Page 10 Champion 10,000

Correct Installation Incorrect Installation

803 778-A / Ref. 226 427-A

4-9. Selecting Weld Cable Sizes*

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

Champion 10,000 TM-945 Page 11

5-1. Front Panel Controls

TM-945 Page 12 Champion 10,000

5-3. Amperage Selection Table For Stick (SMAW) Electrodes

Ref. 202 069-A

= Check = Change = Clean

Fuel Level Oil Level Oil, Fuel Spills

Spark Arrestor Screen

Battery Terminals Cooling System Oil

= Check = Change = Clean

Fuel Level Oil Level Oil, Fuel Spills

Spark Arrestor Screen

Battery Terminals Cooling System Oil