t4424b d302k 3 + 12 cc/cv diesel welder - red-d-arc technical manual.pdf · air carbon arc (cac-a)...

TM-4424B April 2005

Eff. w/Serial Number LE185330 AndFollowing

Processes

Description

Air Carbon Arc (CAC-A) Cuttingand Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Manufacturer’s Rating Label 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, And Engine Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, And Operating Angles 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Volt-Ampere Curves 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Fuel Consumption 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Duty Cycle And Overheating 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. AC Generator Power Curve 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Mounting Welding Generator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Installing Exhaust Pipe 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Activating The Dry Charge Battery (If Applicable) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Connecting The Battery 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Engine Prestart Checks 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Connecting To Weld Output Terminals 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Selecting Weld Cable Sizes* 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Connecting To Remote 3 Pin Receptacle RC13 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Connecting To Remote 14 Receptacle RC14 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING WELDING GENERATOR 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls (See Section 5-2) 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Front Panel Controls (See Section 5-1) 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Process/Contactor Switch 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Lift-ArcE Start Procedure 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Remote Voltage/Amperage Control 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING AUXILIARY EQUIPMENT 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. 115 Volt And 230 Volt Receptacles 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Checking Generator Brushes 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Maintenance Label 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Servicing Air Cleaner 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Servicing Engine Cooling System 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Adjusting Engine Speed 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Servicing Fuel And Lubrication Systems 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9. Overload Protection 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10. Voltmeter/Ammeter Help Displays 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − THEORY OF OPERATION 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − EXPLANATION OF ELECTRICAL PARTS 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 10 − TROUBLESHOOTING 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Troubleshooting Tables 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) 52 . . . . . . . . . . . . . . 10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) 54 . . . . . . . . . . . . . . . . . . . . . . . . 10-4. Waveforms For Sections 10-2 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5. Filter Board PC6 Testing Information 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6. Filter Board PC6 Test Point Values 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7. Main Control Board PC1 Testing Information 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8. Main Control Board PC1 Test Point Values 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9. Voltage Regulator Board PC3 Testing Information 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-10. Voltage Regulator Board PC3 Test Point Values 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11. Meter Display Board PC2 Testing Information 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12. Meter Display Board PC2 Test Point Values 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13. Replacing Brushes And Cleaning Slip Rings 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-14. Checking Unit Output After Servicing 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − DISASSEMBLY AND REASSEMBLY 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Disassembly Of Unit 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Disassembly Of Generator 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Replacing Rectifier SCR Modules 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − ELECTRICAL DIAGRAMS 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 13 − RUN-IN PROCEDURE 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Wetstacking 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2. Run-In Procedure Using Load Bank 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3. Run-In Procedure Using Resistance Grid 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-4424 Page 1D302K 3+12

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING1-1. Symbol Usage

OM-4424E - 1/05, safety_rtm 8/03

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

� Marks a special safety message.

� Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Servicing Hazards

� The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard.

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

� During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Stop engine before testing or repairing unit un-

less the procedure specifically requires an en-ergized unit.

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

� Do not leave live unit unattended.

� When testing live unit, use the one-hand method. Do not put bothhands inside unit. Keep one hand free.

SIGNIFICANT DC VOLTAGE exists after stoppingengine on inverters.� Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

MOVING PARTS can cause injury.

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

� Have only qualified people removeguards or covers for maintenance andtroubleshooting as necessary.

� Keep hands, hair, loose clothing, and tools away from mov-ing parts.

� Before working on generator, remove spark plugs or injec-tors to keep engine from kicking back or starting.

� Block flywheel so that it will not turn while working on gener-ator components.

� Reinstall panels or guards and close doors when servicingis finished and before starting engine.

FLYING METAL can injure eyes.

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

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

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

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

ENGINE EXHAUST GASES can kill.

� Do not breathe exhaust fumes.� Use in open, well-ventilated areas, or vent ex-

haust outside and away from any building air in-takes.

FUEL can cause fire or explosion.

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

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

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

BATTERY EXPLOSION can BLIND.

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

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

� Do not allow tools to cause sparks when working on a battery.

� Do not use welder to charge batteries or jump start vehicles.

� Observe correct polarity (+ and −) on batteries.

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

BATTERY ACID can BURN SKIN and EYES.

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

TM-4424 Page 2 D302K 3+12

STEAM AND HOT COOLANT can burn.

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

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

� If the engine is warm, checking is needed, andthere is no overflow tank, follow the next twostatements.

� Wear safety glasses and gloves and put a rag over radiator cap.

� Turn cap slightly and let pressure escape slowly before completelyremoving cap.

MAGNETIC FIELDS can affect pacemakers.

� Pacemaker wearers keep away from servicingareas until consulting your doctor.

FALLING UNIT can cause injury.

� Use equipment of adequate capacity to lift andsupport unit and components.

� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

� Securely attach components to lifting equip-ment.

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

HOT PARTS can cause severe burns.

� Allow cooling period before servicing.� Wear protective gloves and clothing when

working on a hot engine.� Do not touch hot engine parts bare-handed.

SHOCK HAZARD from testing.

� Stop engine before making or changing meterlead connections.

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

� Read instructions for test equipment.

TILTING OR TIPPING can cause injury.

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

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

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

H.F. RADIATION can cause interference.

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

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

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

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

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

OVERUSE can cause OVERHEATING.

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

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

READ INSTRUCTIONS.

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

� Consult the Owner’s Manual for welding safetyprecautions.

� Use only genuine replacement parts.

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

1-3. California Proposition 65 Warnings� Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

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

For Gasoline Engines:� Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines:� Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

1-4. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: “The body of evidence, in thecommittee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.”However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away fromoperator as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.

TM-4424 Page 3D302K 3+12

SECTION 2 − DEFINITIONS

2-1. Warning Label Definitions

3/96

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Do not smoke and keepmatches and flames away frombattery.

3 Sparks can cause batterygases to explode. Batteryexplosion can blind and injure.Wear a face shield.

4 Battery acid can burn skin. Donot spill acid.

5 Read Owner’s Manual.

6 Wear rubber gloves.7 Dead battery

8 Engine block

9 Fully charged battery

10 Do not connect last negativecable to dead battery − connectinstead to engine block.

11 Jumper cables − observepolarity and make connectionsin numbered sequence shown.

12 Once dead battery is charged,disconnect cables in sequenceshown.

1

S-176 108

+ −

+ −

1 4

2 3

−+

+ −

+ −

4 1

3 2

2 3 4 5 6

10

11

7

8 9 12

S-176 106 3/96


2 Moving parts, such as fans,rotors, and belts, can cutfingers and hands and causeinjury. Keep away from movingparts.

1

2

6/02

1


2 Ether will damage engine. Donot use ether as a starting aid.

3 Read Owner’s Manual.4 Use glow plugs for 10−25

seconds to aid starting in coldweather.

2 3 4

TM-4424 Page 4 D302K 3+12

3/96


2 Hot muffler and exhaust pipescan cause severe burns. Donot touch hot muffler or pipes.

1

S-176 230

2

3/96

1

2

4

3

5

6


2 Engine fuel plus flames orsparks can cause fire.

3 Do not smoke while fueling or ifnear fuel.

4 Stop engine before fueling.

5 Do not fuel a hot engine.

6 Use Diesel Fuel only.

S-176 104

3/96


2 Falling equipment can causeserious injury and damage.

3 Use lifting eye to lift or moveunit only. Use properequipment when lifting.

4 Do not use lifting eye to lift andsupport unit and trailer or otherheavy devices or accessories.

1

2 3 4

TM-4424 Page 5D302K 3+12


2 Fire hazard from leakingengine fuel. Fire can result fromwelding on base atnon-designated areas causinga possible fuel leak.

3 Fuel tank is located insidebase.

4 Do not weld on base of unit.

5 Weld only on supplied bracketsor bolt unit down.

1

5

3 4

2


2 Electric shock from wiring cankill.

3 Moving parts, such as fans,rotors, and belts, can cutfingers and hands and causeinjury. Keep away from movingparts.

1

2

3

TM-4424 Page 6 D302K 3+12

3/96

1 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.

2 Read Owner’s Manual. Readlabels on unit.

3 Use Diesel Fuel only, and fillfuel tank. Leave room forexpansion.

4 Warning! Watch Out! Thereare possible hazards asshown by the symbols. ReadOwner’s Manual. Followinstructions to activatebattery.

5 Check oil level. Add oil ifnecessary.

6 During the first 50 hours ofoperation, keep welding loadabove 200 amperes. Do notweld below 200 amperes ofoutput.

7 After the first 50 hours ofoperation, change the oil andoil filter.

+2

1 +

4

DIESEL

API CD-MIL L 2104D,CD/SE, CD/SF

3

S-177 571

0 − 50 h Std. 0 − 200A200A

5

50 h Std.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

TM-4424 Page 7D302K 3+12

2-2. Manufacturer’s Rating Label

219 870−D

TM-4424 Page 8 D302K 3+12

2-3. Symbols And Definitions

Some symbols are found only on CE products.NOTE

Stop EngineFast (Run, Weld/

Power) Slow (Idle) Start Engine

Starting Aid(Preheat) Battery (Engine)

Engine OilPressure Engine Oil

Check Injectors/Pump

Check ValveClearance Fuel

Protective Earth(Ground)

Positive NegativeCertified/Trained

Mechanic Welding Arc

A Amperes V Volts Panel/Local Remote

EngineAir Temperature Or

EngineTemperature

OutputAlternating

Current

Stick (SMAW)Welding

Constant Current(CC)

MIG (GMAW)Welding TIG (GTAW)

Time h Hours s Seconds 1 Single Phase

3 Three PhaseRead Operator’s

Manual Circuit BreakerDo Not SwitchWhile Welding

ElectrodeConnection Work Connection 3

G

Engine-Driven,Three-Phase

Alternator WithRectifier

Hz Hertz

X Duty Cycle U0Rated No Load

Voltage (Average) U2ConventionalLoad Voltage n

Rated LoadSpeed

n1Rated Idle

Speed n0Rated No Load

Speed I Current I2Rated Welding

Current

Contactor On Arc Force (Dig) Lift-Arc TIG

TM-4424 Page 9D302K 3+12

SECTION 3 − SPECIFICATIONS

3-1. Weld, Power, And Engine Specifications

WeldingMode

Weld OutputRange

Rated WeldingOutput

MaximumOpen-CircuitVoltage

Generator PowerRating Engine Fuel

Capacity

CC/DC20 − 410 A

400 A, 23 Volts DC,40% Duty Cycle

300 A, 32 Volts DCCC/DC

20 410 A 300 A, 32 Volts DC60% Duty Cycle

250 A, 30 Volts DC100% Duty cycle

65

Single-Phase,10 kVA/kW, 84 A,

Kubota 1505 EBG1Water-Cooled, 11.5 gal

CV/DC 14 − 40 V

400 A, 23 Volts DC,30% Duty Cycle

300 A, 29 Volts DC60% Duty Cycle

250 A, 26.5 Volts DC100% Duty cycle

65 10 kVA/kW, 84 A,120 V AC,

60 Hz

Water Cooled,Four-Cylinder,

20.2 HP Diesel Engine

11.5 gal(43.5 L)

3-2. Dimensions, Weights, And Operating Angles

Dimensions

Height32 in (813 mm)

35-3/4 in (908 mm)(to top of lift eye)

G

Width

26-1/4 in (667 mm)(mtg. brackets turned in)

28-3/4 in (730 mm)(mtg. brackets turned out)

� Do not exceed tilt angles or engine couldbe damaged or unit could tip.

� Do not move or operate unit where it couldtip.

Depth 56 in (1422 mm)

A 56 in (1422 mm)A

B 54 in (1372 mm) BA

C

C 52 in in (1321 mm)

D 2 in (51 mm)

E 26 in (660 mm) 30°F 7/8 in (22 mm)

20°30°

G 27-3/4 in (705 mm) H20°20°

30

H9/16 in (14 mm) Dia.

4 Holes

Front Panel End 20°

Weight FE

D

No fuel: 1040 lb (471 kg)

w/ fuel: 1139 lb (516 kg)

E

TM-4424 Page 10 D302K 3+12

3-3. Volt-Ampere Curves

217 517 / 217 516 / 217 518

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

A. Stick Mode

B. MIG Mode

C. TIG Mode

DC

VO

LTS

DC AMPERES

0 100 200 300 400 500

1009080706050403020100

MINMAX300

0 100 200 300 400 500

100

80

60

40

20

0

DC

VO

LTS

DC AMPERES

DC

VO

LTS

DC AMPERES

0 100 200 300 400 500

100

80

60

40

20

0

MIN MAX300

TM-4424 Page 11D302K 3+12

3-4. Fuel Consumption

The curve shows typical fuel useunder weld or power loads.

217 509

IDLE

DC WELD AMPERES AT 100% DUTY CYCLE

U.S

. GA

L/H

R.

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

0 50 100 150 200 250 300 350 400

Continuous Welding

3-5. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

� Exceeding duty cycle candamage unit and voidwarranty.

100% Duty Cycle At 250 Amperes

217 515

10 15 20 25 30 40 50 60 80 100

CCCV

1000

800

600500

400

300250200

150

100

WE

LD A

MP

ER

ES

% DUTY CYCLE

TM-4424 Page 12 D302K 3+12

3-6. AC Generator Power Curve

217 519

The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacles.

0 40 80 120 160

0 20 40 60 80

AC AMPERES IN 120 V MODE

AC AMPERES IN 240 V MODE

300

250

200

150

100

50

0

150

125

100

75

50

25

0

AC

VO

LTS

Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART

TM-4424 Page 13D302K 3+12

SECTION 4 − INSTALLATION

install3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274

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

� Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.

� If unit does not have GFCI re-ceptacles, use GFCI-protectedextension cord.

� See Section 4-2 for mounting in-formation.

Grounding:

1 Equipment Grounding Terminal(On Front Panel)

2 Grounding Cable (Not Supplied)

3 Metal Vehicle Frame

Connect cable from equipmentground terminal to metal vehicleframe. Use #10 AWG or larger insu-lated copper wire.

Electrically bond generator frame tovehicle frame by metal-to-metal contact.

GND/PE

12

3

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

Movement

Airflow Clearance

4-1. Installing Welding Generator

OR

Grounding

� Bed liners, shipping skids, and some runninggears insulate the welding generator from thevehicle frame. Always connect a ground wirefrom the generator equipment grounding termi-nal to bare metal on the vehicle frame as shown.

OR

Location

OR

TM-4424 Page 14 D302K 3+12

4-2. Mounting Welding Generator

Tools Needed:

9/16 in

2

23

4

Welding Unit In Place

Bolting Unit In Place

� Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Weldonly on the four mountingbrackets or bolt unit down.

� Do not mount unit by sup-porting the base only at thefour mounting brackets.Use cross-supports to ade-quately support unit and pre-vent damage to base.

Mounting Surface:

1 Cross-Supports

2 Mounting Brackets (Supplied)

Mount unit on flat surface or usecross-supports to support base.Secure unit with mounting brack-ets.

3 1/2 in Bolt And Washer(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws(Supplied)

To Bolt Unit In Place:

Remove hardware securing thefour mounting brackets to the base.Reverse brackets and reattach tobase with original hardware.

Mount unit to truck or trailer with 1/2in (12 mm) or larger hardware (notsupplied).

To Weld Unit In Place:

Weld unit to truck or trailer only atthe four mounting brackets.

1

Inadequate support.

2

Supporting The Unit

Using Mounting Brackets

Ref install3 6/04 803 274 / 190 250-A / 803 231

� Do not use flexible mounts.

1

OR

TM-4424 Page 15D302K 3+12

4-3. Installing Exhaust Pipe

1/2 in

Tools Needed:

803 582 / Ref. 214 777-E

� Stop engine and let cool.

� Point exhaust pipe in desired di-rection but always away from frontpanel and direction of travel.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

TM-4424 Page 16 D302K 3+12

4-4. Activating The Dry Charge Battery (If Applicable)

Remove battery from unit.

1 Eye Protection − SafetyGlasses Or Face Shield

2 Rubber Gloves

3 Vent Caps

4 Sulfuric Acid Electrolyte(1.265 Specific Gravity)

5 Well

Fill each cell with electrolyte tobottom 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.

6 Battery Charger

� Read and follow all instruc-tions supplied with batterycharger.

Charge battery for 12 minutes at 30amperes or 30 minutes at 5 am-peres. Disconnect charging cablesand install battery.

� When electrolyte is low, addonly distilled water to cells tomaintain proper level.

3

Tools Needed:

1

2

4

6

30 A For 12 Minutes

5 A For 30 Minutes

OR

+

−

5

drybatt1 1/98 − 0886

rubber gloves

glasses

TM-4424 Page 17D302K 3+12

4-5. Connecting The Battery

1/2 in

−

+

� Connect Negative (−) Cable Last.

Tools Needed:

Ref. 214 777-E / 803 581−D / S-0756-C

� Close door after connecting battery.

Notes

TM-4424 Page 18 D302K 3+12

4-6. Engine Prestart Checks

� Check all engine fluids daily.

Engine must be cold and on a level surface.Unit is shipped with 20W break-in oil.Automatic shutdown system stops engine ifoil pressure is too low or coolant tempera-ture is too high.

� This unit has a low oil pressure shut-down switch. However, some condi-tions may cause engine damage beforethe engine shuts down. Check oil leveloften and do not use the oil pressureshutdown system to monitor oil level.

Follow run-in procedure in engine manual.If unburned fuel and oil collect in exhaustpipe during run-in, see Section 13.Fuel� Do not use gasoline. Gasoline will

damage engine.The unit is shipped with enough fuel to pre-vent air from entering fuel system. Add freshdiesel fuel before starting (see engine main-tenance label for fuel specifications). Leavefiller neck empty to allow room forexpansion.

Do not run out of fuel or air will enter fuel sys-tem and cause starting problems. See en-gine manual to bleed air from fuel system.

Oil

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).

Coolant

Check coolant level in radiator before start-ing unit the first time. If necessary, add cool-ant to radiator until coolant level is at bottomof filler neck.

Check coolant level in recovery tank daily.If necessary, add coolant to recovery tankuntil coolant level is between Cold Full andHot Full levels. If recovery tank coolant levelwas low, also check coolant level in radiator.Add coolant if level is below bottom of radia-tor filler neck.

Unit is shipped with an engine coolant mix-ture of water and ethylene glycol base anti-freeze rated to −34° F (−37° C). Add anti-

freeze to mixture if using the unit in tempera-tures below −34° F (−37° C).

Keep radiator and air intake clean and freeof dirt.

� Incorrect engine temperature candamage engine. Do not run enginewithout a properly working thermo-stat and radiator cap.

� To improve cold weather starting:

Use Preheat switch (see Section 5-1).

Keep battery in good condition. Storebattery in warm area.

Use fuel formulated for cold weather(diesel fuel can gel in cold weather).Contact local fuel supplier for fuel in-formation.

Use correct grade oil for cold weather(see Section 7-3).

Full

Capacity:6 qt (5.7 L)

Diesel

Full

Hot Full

Cold Full

Check radiator coolantlevel when fluid is low in

recovery tank.

Coolant Recovery Tank

803 581−D

Full

TM-4424 Page 19D302K 3+12

4-7. Connecting To Weld Output Terminals

Tools Needed:

3/4 in

� Stop engine.

1 Work (−) Weld Output Terminal

2 CV (Wire) Weld Output Terminal

3 CC (Stick/TIG) Weld Output Terminal

Stick and TIG WeldingFor Stick and TIG welding Direct Current Elec-trode Positive (DCEP), connect electrodeholder cable to CC (Stick/TIG) terminal onright and work cable to Negative (−) terminalon left.

For Direct Current Electrode Negative(DCEN), reverse cable connections.

Use Process/Contactor switch to select typeof weld output (see Section 5-3).

MIG and FCAW WeldingFor MIG and FCAW welding Direct CurrentElectrode Positive (DCEP, connect wire feed-er cable to CV (Wire) terminal on right andwork cable to Work/Negative (−) terminal onleft. Use Process/Contactor switch to selecttype of weld output (see Section 5-3).

For Direct Current Electrode Negative(DCEN), reverse cable connections.

803 560 / 214 777-E1 2 3

4-8. Selecting Weld Cable Sizes*

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

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

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Weld OutputTerminals

� Stop engine beforeconnecting to weld out-put terminals.

� Do not use worn, dam-aged, undersized, orpoorly spliced cables.

WeldingAmperes

10 − 60%DutyCycle

60 − 100%DutyCycle

10 − 100% Duty Cycle

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)

2 ea. 2/0(2x70)

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

2 ea. 3/0(2x95)

2 ea. 3/0(2x95)

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

2 ea. 3/0(2x95)

2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

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

2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

2 ea. 4/0(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)

2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

3 ea. 3/0(3x95)

3 ea. 3/0(3x95)

* This chart is a general guideline and may not suit all applications. If cables overheat, 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 920-735-4505.

TM-4424 Page 20 D302K 3+12

4-9. Connecting To Remote 3 Pin Receptacle RC13

Socket Socket Information

A Remote control circuit common.

REMOTEOUTPUT

CONTROL

B DC input command signal: 0 to+10 volts from min. to max. ofremote control with Voltage/Amperage control at max.

803 580

C Output to remote control: 0 to+10 volts dc.

4-10. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

24 VOLTS AC

A 24 volts ac. Protected by circuitbreaker CB8.

24 VOLTS AC

B Contact closure to A completes24 volt ac contactor controlcircuit.

C Output to remote control:+10volts dc in MIG mode; 0 to +10volts dc in Stick or TIG mode.

REMOTEOUTPUT

D Remote control circuit common.OUTPUT

CONTROL E DC input command signal: 0 to+10 volts from min. to max. ofremote control with Voltage/Amperage Adjust control atmax.

115 VOLTS ACI

115 volts, 10 amperes, 60 Hzac. Protected by circuit breakerCB7.

OR

JContact closure to I completes115 volt ac contactor controlcircuit.

OR

FCurrent feedback: 1 volt per100 amperes.

H Voltage feedback: 1 volt per 10arc volts.

803 580 GND K Chassis common.

NEUTRAL G Circuit common for 24 and 115volt ac circuit.

*The remaining sockets are not used.

TM-4424 Page 21D302K 3+12

Notes

Over 80,000 trained

since 1930!400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Start Your Professional

Welding Career Now!

TM-4424 Page 22 D302K 3+12

SECTION 5 − OPERATING WELDING GENERATOR

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

214 777-E / 803 581−D

2 1 547 9 10 11 12 68

3

Stop

TM-4424 Page 23D302K 3+12

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

Engine Starting Controls

1 Start/Preheat Switch

Use switch to start engine and operate glowplug for cold weather operation.

Engine runs at weld/power speed continu-ously.

Turn switch to Preheat position to operate theglow plug and heat the combustion chambersbefore cranking engine (see starting instruc-tions following).

2 Engine Shutdown Switch

Push switch down to stop engine.

3 Engine Stop Lever

Use lever to stop engine if Engine Shutdownswitch does not work.

� The Engine Stop lever shuts off the fuelsupply. However, the Engine Stop leverwill not stop the engine if the engine candraw fuel-rich air from the surroundingatmosphere (oil refineries).

To Start:

� If engine does not start, let engine cometo a complete stop before attempting re-start.

Above 41� F (5� C): turn Start/Preheat switchto Preheat position for 5 seconds and thenturn switch to Start position. Release Start/Preheat switch when engine starts.

Below 41� F (5� C):Turn Start/Preheat switch to Preheat positionfor 15 seconds and then turn switch to Start.Release Start/Preheat switch when enginestarts.

To Stop:

Push Engine Shutdown switch down to stopengine.

Engine Gauges, Meters, And Lights4 Fuel Gauge/HourmeterUse gauge to check fuel level or total engineoperating hours.To check fuel level or engine hours when en-gine is not running, turn Start/Preheat switchto Preheat position.5 Engine Indicator LightLight goes on and engine stops if engine tem-perature exceeds 230° F (110° C) or engineoil pressure is below 10 psi (69 kPa).

� Normal engine temperature is 180 - 203� F (82 - 95� C). Normal oil pressure is 30- 60 psi (207 - 414 kPa).

� Do not run engine until trouble isfixed.

6 Battery AmmeterUse gauge to check amperage output to thebattery. The gauge reads near 0 (zero) whenthe engine is running. If gauge is at a negativenumber, the battery is discharging.Weld Controls7 Remote 14 Pin Receptacle8 Remote 3 Pin ReceptacleUse receptacles to connect remote controls,wire feeders, and tools.When a remote control is connected to a Re-mote receptacle, the Auto Sense Remote fea-ture automatically switches voltage/amper-age control to the remote control connected tothat receptacle (see Sections 4-9, 4-10 and5-5).With remote control connected, weld output isdetermined by a combination of front paneland remote control voltage/amperage set-tings.If no remote control is connected to a Remotereceptacle, the front panel Voltage/Amperagecontrol adjusts voltage and amperage.

� If remote controls are connected to bothremote receptacles, remote amperage/voltage control is only available throughthe Remote 3 Pin receptacle. However,the Remote 14 Pin receptacle still pro-vides remote contactor control.

� If a remote device connected to RemoteReceptacle RC13 or RC14 is faulty or isdisconnected, the meters display Help 25(see Section 7-10). Clear fault by stop-ping and restarting the unit or by turningProcess/Contactor switch to anotherposition.

9 Process/Contactor Switch

See Section 5-3 for Process/Contactorswitch information.

10 Voltage/Amperage Control

With Process/Contactor switch in any Stick orTIG setting, use control to adjust amperage.With Process/Contactor switch in any Wire(MIG) position, use control to adjust voltage.With Voltage/Amperage Adjust Switch in Re-mote position, control limits the remote am-perage in Stick or TIG mode, but has no effectin Wire (MIG) modes.

Weld Meters

� Weld meters also work in combination todisplay troubleshooting help codes (seeSection 7-10).

11 DC Voltmeter

Voltmeter displays preset voltage (MIG weld-ing) with contactor off, and actual output volt-age with the contactor on. Voltmeter displaysvoltage at the weld output terminals, but notnecessarily the welding arc due to resistanceof cable and connections.

To set voltage, turn contactor off and turn Pro-cess/Contactor switch to Wire position. TurnV/A control until desired voltage is displayedon Voltmeter. When welding is finished, volt-meter displays weld voltage and then defaultsto preset voltage.

12 DC Ammeter

Ammeter displays preset amperage (Stickand TIG only) when not welding, and actualoutput amperage when welding.

To set amperage, turn Process/Contactorswitch to Stick or TIG position. Turn V/A con-trol until desired amperage is displayed onAmmeter. When welding is finished, ammeterdisplays weld amperage and then defaults topreset amperage.

TM-4424 Page 24 D302K 3+12

5-3. Process/Contactor Switch1 Process/Contactor Switch

� Weld output terminals are ener-gized when Process/Contactorswitch is in a Weld Terminals Al-ways On position and the engineis running.

Use switch to select weld process andweld output on/off control (see table be-low).

Place switch in Remote On/Off SwitchRequired positions to turn weld output onand off with a device connected to theRemote 14 receptacle.

Place switch in Weld Terminals AlwaysOn positions for weld output to be onwhenever the engine is running.

Use Stick mode for air carbon arc(CAC-A) cutting and gouging.

When switch is in Stick mode, select oneof four arc drive (dig) settings to provideadditional amperage during low voltage(short arc length) conditions and prevent“sticking” electrodes. Turn control from Ato D to increase arc drive (dig) from minto max.

Use the Lift-Arc TIG mode for TIG(GTAW) welding using the Lift-Arc TIGstarting procedure (see Section 5-4).

803 560 / 214 777−E

Process/Contactor Switch Settings

Switch Setting Process Output On/Off ControlSwitch Setting Process Output On/Off Control

Remote On/Off Switch Required −TIG LIft Arc GTAW With HF Unit, Pulsing Device, Or Re-

mote Control At Remote 14 Receptacle

Remote On/Off SwitchRequired − Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle

Remote On/Off SwitchRequired − CV Feeder

Using Remote

MIG (GMAW)w/Constant Speed Feeder At Remote 14 Receptacle

Weld Terminals Always On − WireMIG (GMAW)

w/Voltage Sensing Feeder Electrode Hot

Weld Terminals Always On − StickStick (SMAW),

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

Weld Terminals Always On − TIG Lift-Arc TIG Lift-Arc (GTAW) Electrode Hot

TM-4424 Page 25D302K 3+12

5-4. Lift-Arc™ Start Procedure

Lift-Arc � TIG

With Lift-Arc� TIG selected, startarc as follows:

1 TIG Electrode

2 Workpiece

Turn gas on. Touch tungstenelectrode to workpiece at weld startpoint. Hold electrode toworkpiece for 1-2 seconds, andslowly lift electrode. Arc is formedwhen electrode is lifted.

Normal open-circuit voltage is notpresent before tungsten electrodetouches workpiece; only a lowsensing voltage is present betweenelectrode and workpiece. Thesolid-state output contactor doesnot energize until after electrode istouching workpiece. This allowselectrode to touch workpiecewithout overheating, sticking, or be-ing contaminated.

Application:

Lift-Arc is used for the DCENGTAW process when HF Startmethod is not permitted, or toreplace the scratch method.

1

1 − 2Seconds“Touch”

Do NOT Strike Like A Match!

2Lift-Arc Start Method

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

TM-4424 Page 26 D302K 3+12

5-5. Remote Voltage/Amperage Control

1 Remote 3 Pin ReceptacleRC13

2 Remote 14 Pin ReceptacleRC14

Connect optional remote control toeither RC13 or RC14 (see Sections4-9 and 4-10 and).

Ref. 214 777-E / 803 580

Example: Combination Remote Amperage Control (Stick)

Adjust Optional Remote ControlSet V/A Control Mid-Range:About 205A

Set Remote Process (Only IfRemote On/Off Control Is

Desired)

Example: Combination Remote Amperage Control (TIG)

Adjust Optional Remote ControlSet V/A ControlMid-Range:About 205 A

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

Min = 20 A DCMax = 205 A DC

Max (205 A DC)

Min (20 A DC)

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

Min = 20 A DCMax = About 205 A DC

Max (205 A DC)

Min (20 A DC)

Connect RemoteControl To RemoteReceptacle RC13

Or RC14

1

2

OR

Connect RemoteControl To RemoteReceptacle RC13

Or RC14

OR

Set Remote Process (Only IfRemote On/Off Control Is

Desired)

TM-4424 Page 27D302K 3+12

SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. 115 Volt And 230 Volt Receptacles

214 777-D

1 2 3 4 5 6

1 115 V 20 A AC GFCI Receptacle GFCI1

2 115 V 20 A AC GFCI Receptacle GFCI2

3 230 V 50 A ACReceptacle RC11

GFCI1 and GFCI2 supply 60 Hz single-phase power at weld/power speed.

Maximum output from GFCI1 or GFCI2 is2.4 kVA/kW.

If a ground fault is detected, GFCI Resetbutton pops out and receptacle does notwork. Check for faulty equipment pluggedin receptacle. Press button to reset GFCIreceptacle.

� At least once a month, run engine atweld/power speed and press test but-ton to verify GFCI is working properly.

RC11 supplies 60 Hz single-phase powerat weld/power speed. Maximum outputfrom RC11 is 10 kVA/kW.

4 Circuit Breaker CB4



CB4 protects GFCI2 and CB6 protectsGFCI1 from overload. If a circuit breakeropens, the receptacle does not work. Pressbutton to reset breaker.

Circuit breaker CB5 protects receptaclesGFCI, GFCI2, RC11 and the generatorwinding from overload. If CB5 opens, thereceptacles do not work. Place CB5 switchin On position to reset circuit breaker.

� Generator power decreases as weldoutput increases.

Combined output of all receptacles is limit-ed to the 10 kVA/kw rating of the generator.

EXAMPLE: If 15 A is drawn from each 115V receptacle , only 26 A is available at the230 V receptacle:

2 x (115 V x 15 A) + (230 V x 26 A) = 10.0 kVA/kW

TM-4424 Page 28 D302K 3+12

SECTION 7 − MAINTENANCE7-1. Routine Maintenance

Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.

Note

Recycle enginefluids.

� Stop engine before maintaining.

� See Engine Manual and MaintenanceLabel for important start-up, service,and storage information. Service unitmore often if used in severe conditions.

* To be done by Factory AuthorizedService Agent.

Every 8 h

Check FluidLevels. SeeSection 4-6.

WipeUp

Spills.

Drain WaterFrom FuelSystem.OIL

Full

FUELWATER

CoolantFull

Every 50 h

Clean Air Filter.See Section 7-4.

Clean AndTightenWeld

Terminals.

Every 100 h

Clean AndTightenBattery

Connections.

Check air cleanerhoses for cracksand loose clamps.

Every 250 h

ReplaceUnreadable

Labels.

1/2 in.(13 mm)

Check BeltTension.

Change Oil. SeeSection 7-8.

Change Oil Filter.See Section 7-8.

Check AndClean SparkArrestor. SeeSection 7-5.

TM-4424 Page 29D302K 3+12

Every 500 h

Repair OrReplace

DamagedCables.

Drain SludgeFrom FuelTank. See

Section 7-8.

FUEL

SLUDGECheck RadiatorFluid Level. See

Section 4-6.

Change FuelFilters. SeeSection 7-8.

Every 1000 h

Service WeldingGenerator Brushes AndSlip Rings. Service More

Often In Dirty Conditions.*

Blow Out OrVacuum Inside.During Heavy

Service,Clean Monthly.

OR

CheckValve

Clearance.*

Every 2000 h

Clean/Set Injectors.*

7-2. Checking Generator Brushes

Ref 214 777−F / S−0233−A


1 Generator Brush With Spring

Mark and disconnect leads at brush hold-er cap. Remove brushes.

Replace brushes if damaged or if brushmaterial is at or near minimum length.

1

5/16 in. (8 mm)Minimum Length

9/16 in. (14.3 mm)New Length

ReplaceDamaged Brushes

TM-4424 Page 30 D302K 3+12

7-3. Maintenance Label

TM-4424 Page 31D302K 3+12

7-4. Servicing Air Cleaner

� Stop engine.

� Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty.

� The air cleaner primary element canbe cleaned but the dirt holding capac-ity of the filter is reduced with eachcleaning. The chance of dirt reachingthe clean side of the filter while clean-ing and the possibility of filter damagemakes cleaning a risk. Consider therisk of unwarrantable equipmentdamage when determining whetherto clean or replace the primary ele-ment.

If you decide to clean the primary ele-ment, we strongly recommend instal-ling an optional safety element to pro-vide additional engine protection.Never clean a safety element. Re-place the safety element after servic-ing the primary element three times.

Clean or replace primary element if dirty(see note above before cleaning). Re-place primary element if damaged. Re-place primary element yearly or after sixcleanings.

1 Housing

2 Safety Element (Optional)

3 Primary Element

4 Dust Cap

5 Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove capand dump out dust. Remove element(s).Wipe dust from inside cap and housingwith damp cloth. Reinstall safety element(if present). Reinstall cap.

� Do not clean housing with airhose.

Clean primary element with compressedair only.

Air pressure must not exceed 100 psi(690 kPa). Use 1/8 in (3 mm) nozzle andkeep nozzle at least 2 in (51 mm) frominside of element. Replace primary ele-ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dustejector down).

Blow Inspect

41 3

5

Keep nozzle2 in (51 mm)

from element.

2

aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 214 777-D

Optional

TM-4424 Page 32 D302K 3+12

7-5. Inspecting And Cleaning Optional Spark Arrestor Muffler

803 582 / Ref. 214 777-E


1 Spark Arrestor Muffler

2 Cleanout Plug

Remove plug and remove any dirtcovering cleanout hole.

3 Exhaust Pipe

Start engine and run at idle speed toblow out cleanout hole. If nothingblows out of hole, briefly cover endof exhaust pipe with fireproofmaterial.


Reinstall cleanout plug.

Tools Needed:

5/16 in

1

2

3

7-6. Servicing Engine Cooling System


1 Radiator Draincock

2 Radiator Cap Cover

Change coolant according to enginemanual. Add coolant according to Sec-tion 4-6).

Run engine until engine reaches normaloperating temperature. Check coolantlevel in recovery tank. Add coolant if nec-essary.

After engine cools, check coolant levelagain and add coolant if necessary.

2

1

803 581−D / Ref 214 777−F

TM-4424 Page 33D302K 3+12

7-7. Adjusting Engine Speed

803 581−D

3

1

2

RPM (Hz)Engine Speed

(No Load)

Weld/Power 1880 (62.6)Maximum


Engine speed is factory set andshould not require adjustment. Af-ter tuning engine, check enginespeed with tachometer or frequen-cy meter. See table for proper noload speed. If necessary, adjustspeed as follows:

Start engine and run until warm.

Turn Process/Contactor switch toStick − Weld Terminals Always Onposition.

1 Lock Nut

2 Adjustment Screw

Loosen nut. Turn screw until engineruns at weld/power speed. Tightennut.

� Do not set engine speed higherthan specified.

3 Engine Stop Lever

Use lever to stop engine if Start/Preheat switch does not work.

� Stop engine.

Close door.

Stop

Tools Needed:

TM-4424 Page 34 D302K 3+12

7-8. Servicing Fuel And Lubrication Systems

803 581 / Ref 214 777−E

Tools Needed:

6

5

2

4


� After servicing, start engineand check for fuel leaks.Stop engine, tighten connec-tions as necessary, and wipeup spilled fuel.

1 Oil Filter

2 Oil Drain Valve And Hose

3 Oil Fill Cap

4 Primary Fuel Filter

5 Secondary Fuel Filter

6 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valvethrough hole in base. See enginemanual and engine maintenancelabel for oil/filter change in-formation.

To replace primary fuel filter:

Turn filter counterclockwise. Re-move filter.

Fill new filter with fresh fuel. Applythin coat of fuel to gasket on new fil-ter. Install new filter and turn clock-wise. Bleed air from fuel system ac-cording to engine manual.

Inspect fuel lines, and replace ifcracked or worn.

To drain water from fuel system:

See engine manual.

To replace secondary fuel filter:

Note direction of fuel flow as indi-cated by arrow on side of filter. Re-move fuel line clamps and discon-nect fuel lines from fuel filter. Re-place filter , reconnect fuel lines,and reinstall clamps.

To drain sludge from fuel tank:

� Beware of fire. Do not smokeand keep sparks and flamesaway from drained fuel. Dis-pose of drained fuel in an en-vironmentally-safe manner.Do not leave unit unattendedwhile draining fuel tank.

� Properly lift unit and securein a level position. Use ade-quate blocks or stands tosupport unit while drainingfuel tank.

Attach 1/2 ID hose to drain valve.Put metal container under drain,and use screwdriver to opensludge drain valve. Close valvewhen sludge has drained. Removehose.

Close door.

1

3

TM-4424 Page 35D302K 3+12

7-9. Overload Protection

803 566 / 803 580 / Ref 214 777−E

1

5 6

3

4

� Stop engine.

1 Fuse F1

F1 protects the stator exciter windingfrom overload. If F1 opens, weld andgenerator power is low or stops en-tirely.

If F1 continues to open, check volt-age regulator board PC3.

� If PC3 senses an overload con-dition (shorted rotor), it protectsitself by stopping weld output.Check rotor and brushes beforereplacing PC3.

2 Circuit Breaker CB1 (NotShown)





CB1 protects the engine battery cir-cuit. If CB1 opens, the engine will notcrank. CB1 automatically resetswhen the fault is corrected. If CB1continues to open, check fuel sole-noid FS1, the fuel pump, throttle so-lenoid TS1, integrated rectifier SR1,engine alternator, glow plug, and cir-cuit boards PC2 and PC3.

CB2 protects the engine wiring har-ness. If CB2 opens, the engine willnot crank. Press button to resetbreaker. If CB2 continues to open,check fuel solenoid FS1, the fuelpump, throttle solenoid TS1, inte-grated rectifier SR1, and circuitboards PC2 and PC3.

CB3 protects part of the weld controlwiring harness. If CB3 opens, weldand generator power output stops. IfCB3 continues to open, check circuitboards PC1, PC2, and PC3.

CB7 protects the 115 volt ac outputto remote receptacle RC14. If CB7opens, 115 volt output to RC14stops. If CB7 continues to open,check remote controls connected toRemote receptacle RC14, and cir-cuit board PC6.

CB8 protects the 24 volt ac output toremote receptacle RC14. If CB8opens, 24 volt output to RC14 stops.If CB8 continues to open, check re-mote controls connected to Remotereceptacle RC14, and circuit boardPC6.

TM-4424 Page 36 D302K 3+12

7-10. Voltmeter/Ammeter Help Displays

Use the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions.

� When a help code is displayednormally weld output hasstopped but generator poweroutput may be okay.

� To reset help displays, stopunit and then restart. See item6 below to reset Help 25 dis-play.

1 Help 20 Display

Indicates a failure of meter displaymodule PC2, or the wiring betweenPC2 and main control module PC1.If this display is shown, check PC1,PC2, and the wiring between PC1and PC2.

2 Help 21 Display

Indicates thermistor TH1 on themain rectifier heat sink has failed.If this display is shown, check TH1.,and the wiring between TH1 andPC1.

3 Help 22 Display

Indicates the rectifier heat sink hasoverheated. If this display is shown,check generator cooling systemand/or reduce duty cycle. Keep en-gine access door closed when run-ning to maintain proper cooling airflow past rectifier. Allow unit to coolbefore restarting.

4 Help 23 Display

Indicates one of the rectifier outputSCR’s has failed. If this display isshown, check the rectifier SCR’s.

5 Help 24 Display

Indicates weld open circuit voltage(OCV) is too high (above 41 voltsdc). If this display is shown, checkmain control module PC1.

6 Help 25 Display

Indicates a remote device con-nected to Remote ReceptacleRC13 or RC14 may be faulty. Help25 is also displayed whenever a re-mote device has been connected toRC13 or RC14 and then discon-nected. Clear fault by stopping andrestarting the unit or by turning Pro-cess/Contactor switch to anotherposition. If problem continues,check the remote device, filterboard PC6, and main control mod-ule PC1.

2

1

HL.P 22

HL.P 23

HL.P 24

HL.P 25

HL.P 20

HL.P 21

6

5

4

3

803 580 / 214 777-E

TM-4424 Page 37D302K 3+12

Notes

TM-4424 Page 38 D302K 3+12

SECTION 8 − THEORY OF OPERATION

1 Engine

Supplies force to turn revolving fields.

2 Revolving Fields (Rotor)Turn at 1885 rpm maximum for weld andpower. The speed and excitation currentof the field coils determine voltages instator windings.

3 Stator WindingsSupply power to exciter, generator pow-er, and weld circuits.

4 Fuse F1Protects exciter windings from over-load.

5 Voltage Regulator Board PC3

Changes ac output of stator windings todc to supply excitation current to the ex-citer revolving field.

Controls field current in response tochanges in output load.

If PC3 senses an overload condition(shorted rotor), it protects itself by stop-ping excitation current (weld and gener-ator power output stops).

6 Circuit Breakers CB4, CB5, andCB6

Protect AC receptacles from overload.

7 AC Receptacles GFCI1, GFCI2and RC11

Provide connection points and power forauxiliary equipment.

8 Circuit Breakers CB7 and CB8

Provide overload protection for 24 and115 volts ac portion of Remote 14 recep-tacle RC14.

9 Filter Board PC6/Remote Recep-tacles RC13 and RC14

PC6 protects unit from high frequency.RC13 connects remote amperage/vol-tage control to unit. RC14 connectsremote amperage/voltage and contac-tor controls to unit.

When a remote control is connected toa Remote receptacle, the Auto SenseRemote feature automatically switchesvoltage/amperage control to the remotecontrol.

10 Voltage/Amperage Control R2Adjusts weld output amperage or volt-age level.

11 Process/Contactor Switch R1

Selects weld process and weld outputon/off control.

Circuit

8

8

BreakerCB7

9

ControlBoardPC1

115 VAC

24 VAC

+10 VDC OutputCommand Voltage

12

3φExciter

Stator Windings

Generator Power

Wel

d

RevolvingFields(Rotor)

Engine

VoltageRegulatorBoard PC3

5

21 3

CurrentFeedback

CircuitBreakers

6

CB4, CB5, CB6

7

4

Fuse F1

ACReceptacles

GFCI1, GFCI2,RC11

CircuitBreaker

CB8Filter BoardPC6/RemoteReceptaclesRC13, RC14

TM-4424 Page 39D302K 3+12

12 Control Board PC1

Controls weld output by changingmain rectifier SCR gate pulses(conduction times) after comparingamperage (CC) or voltage (CV)feedback to selected voltage/am-perage signal.

13 Thermostat TH1Thermostat opens and stops allweld output if unit overheats.

14 Meter Board PC2

Displays preset and actual (rectifiedand filtered) values of the weld volt-age and amperage.

15 Main Rectifier

Changes ac weld current to dc.

Works with PC1 (item 12) to con-trols weld output by changing recti-fier SCR gate pulses (conductiontimes) after comparing voltage (CV)or amperage (CC) feedback to se-lected voltage or amperage signal.

16 Burden Resistor R3Provides a path for a minimum SCRholding current to flow.

17 Hall Device HD1

Provides current feedback signal toPC1.

18 Stabilizer Z1

Smooths (filters) weld outputcurrent.

19 Capacitor Bank C10Filters the dc output voltage of mainrectifier.

20 Work (−), CC, And CV WeldOutput Terminals

Provide weld output and allowchanging of output polarity.

AC Or DC Control Circuits

Weld Current Circuit

External Circuits

Thermostat

13

TH1

SCRGatingSignals

17

Hall Device

HD1

16

18

CurrentFeedback

StabilizerZ1

20

20

Electrode

Work

19

CapacitorBank C10

20

CC or CVVoltage

Feedback

MainRectifier

15

3φ Power

CV WeldOutput

Terminal

CC WeldOutput

Terminal

Work (−) WeldOutput

Terminal

11

Process/ContactorSwitch R1

14

MeterBoard PC2

10

Voltage/AmperageControl R2

CC

CVBurden

Resistor R3

TM-4424 Page 40 D302K 3+12

SECTION 9 − EXPLANATION OF ELECTRICAL PARTSelect_parts 7/04

9-1. Safety Precautions − Read Before Using This Guide

� WARNING: ELECTRIC SHOCK can kill.

� Disconnect input power or stop engine before servicing.

� Do not touch live electrical parts.� Do not operate machines with covers removed.

� Have only qualified persons install, use, or service equipment.

PART NAME FUNCTION PICTURE CIRCUIT SYMBOL

BATTERY A source of DC voltage. Typically used inEngine Driven equipment.

+

BRUSHES/SLIPRINGS

Components that allow electrical connectionsbetween stationary and rotating contacts.

SLIPRINGS

BRUSHES

CAPACITOR A device that stores electrical energy. Largecapacitors or a “bank” of capacitors can beused to “smooth out” the DC welding arc in aMIG welding power source. Smaller “disk”capacitors can be used for HF protection.

C1 C1

POLARIZED NON-POL.+

CHASSIS The green ground wire of a primary cord isconnected to the machine frame (chassis) forsafety. Also, you may find many “HF bypass”capacitors connected to chassis to reduceHigh Frequency interference. Expect to seethis symbol used numerous times in circuitdiagrams. The picture shown here is from anEngine Drive where several wires includingthe battery are connected to the chassis.

CIRCUIT BREAKER A protection device that breaks a circuit whencurrent levels exceed its rating. Unlike a fusethat needs to be replaced when blown, acircuit breaker can be reset.

CB1

CIRCUIT COMMON When many wires are connected together,rather than showing all the “lines” and “dots”,this symbol may appear on the circuit. Lookfor other Circuit Common symbols on acircuit diagram. For instance, say 10 symbolsare found on a circuit, this means all tenpoints are electrically tied together.

TM-4424 Page 41D302K 3+12

PART NAME CIRCUIT SYMBOLPICTUREFUNCTION

CLAMP A spring-loaded connection device. A goodexample would be the “work clamp” used toconnect the weld cable from a power sourceto the workpiece that will be welded.

CONTACTOR A heavy duty relay. Usually used to makeand break the welding arc or primary power. W COIL

NRM OPENPOINTS

W

CURRENTTRANSFORMER

A transformer that produces an AC voltageused for measuring purposes. The primarywinding is in series with the circuit carryingthe current to be measured. Its main use inengine-driven equipment is to activate the“Automatic Idle” circuit by sensing weldingcurrent or auxiliary power current.

CT1

OR

CT1

DASHED LINE A dashed line between parts means there isa mechanical connection between theseparts. When a dashed line boxes in parts,this means the parts make up an option orare combined into one part. In all cases,dashed lines do not conduct electricity. Thepicture shown is a combination fan motor andtransformer in one part.

FM

DIODE A device that allows current to flow in onedirection only. Most common use is tochange AC to DC.

D1

FAN MOTOR This device provides cooling of the internalparts of a welding power source.

FM

FUSE A protection device, usually an enclosedpiece of wire that melts and breaks the circuitwhen the current exceeds the fuse rating.

F1

GAS OR WATERSOLENOID(VALVE)

These are electromechanical devices used tostart or stop the flow of shielding gas orwater. GS1

ORWS1

HALL DEVICE Produces a small DC voltage proportional tothe current it is sensing (usually weldingcurrent). This feedback signal can be used toregulate the welding output (line voltagecompensation). It may even be used to drivean ammeter.

HD1

TM-4424 Page 42 D302K 3+12


IGBT A device that is used as an “electronicswitch”. When a signal is applied to the gate(G), current is allowed to flow from the emitter(E) to the collector (C). This device is typicallyused in “Inverter” designed welding machinesto control the welding output.

C1

G1 (B1)

E1

INTEGRATEDBRIDGERECTIFIER

An arrangement of four diodes used tochange AC to DC.

AC

AC−

+AC AC

+

_

INTEGRATEDCIRCUIT

IC’s often called “chips” provide a completecircuit function with inputs and outputs. Agood example would be the “Pulse WidthModulation” chip used in many wire feederdesigns.

U1

JUMPER LINK Usually, the jumper link is a piece of brassthat connects two terminals together. Dashedlines indicate possible locations for otherjumper links.

TE1

LIGHT EMITTINGDIODE

This device usually referred to by its initialsLED is used to tell you when a particularcircuit is activated. This function is veryhelpful for troubleshooting.

D1

MAGNETICAMPLIFIER

This device usually referred to as a“Mag-Amp” is made up of coil windings andan iron core similar to a transformer. Itcontrols a large welding current by varying asmall “control current”.

MA1

METER A measuring device. A “voltmeter” is a goodexample.

VV = voltmeterA = ammeter

HM = hourmeter

MOSFET A device that is used as an “electronicswitch”. When a signal is applied to the gate(G), current is allowed to flow from the source(S) to the drain (D). This device can be usedto control a relay, the speed of a motor, oreven the output of a welding machine.

D

G

AS S

TM-4424 Page 43D302K 3+12


MOTOR A device that converts electrical energy intomechanical energy. Typically used to feedwire in a MIG welding system, or pumpcoolant in a recirculating liquid-coolingsystem.

M1

M1 = DC

= AC

OPERATIONALAMPLIFIER

Usually referred to as an “Op-Amp”, this ICchip is very versatile and widely used on PCboards. A typical use might be as a“comparator”, comparing the commandsignal to the feedback signal allowing thewelding output to be kept constant.

A1

+

_

OPTICALCOUPLER

A device that uses “light” to get electricalseparation (isolation). This eliminates noisethat might be in one circuit from affectinganother circuit.

OC1

PILOT LIGHT A light located on the front panel whichindicates if the machine is on or off. PL

1

POTENTIOMETERORRHEOSTAT

Both devices have a moveable brush thatmakes contact along a resistor, allowing youto easily change the resistance measured atthe brush (sometimes referred to as a wiper).Their primary purpose is to give the operatora way to adjust welding parameters such aswire speed, preflow time, voltage,inductance, etc.

CW = CLOCKWISE

R1

CCW =COUNTER-CLOCKWISE

PLUG A connection device that hangs loose withwires coming out the back of it. Please notethat the plug terminals can be either male orfemale.

PLG1PLG =

LOOSE

MALEFEMALE

RECEPTACLE A connection device that is mounted or fixed.Just like a plug, the terminals can be eithermale or female.

RC1RC =

MOUNTED

MALE

FEMALE

RELAY−−COIL ANDCONTACTS,NORMALLY OPENAND NORMALLYCLOSED

This is an electromechanical device whosecontacts change state (the normally openpoints close and the normally closed pointsopen) when proper voltage is applied to thecoil. These contact points in turn may controla fan motor, gas solenoid, contactor, etc.Circuit diagrams (schematics) always showthe contact points in the power off state.

CR1 CR1

COIL

NRM OPENPOINTS

NRM CLOSEDPOINTS

CR1

RESISTOR A device which resists the flow of electriccurrent. Uses include limiting the current for amotor brake circuit in a wire feeder and fordischarging a capacitor.

FIXED

FIXED TAPPED

R1

R1

RIBBON CABLE A connection device where the wires are laidout flat. Usually to connect circuits from onePC board to another PC board.

26-CONDUCTORCABLE

RC54 RC44

TM-4424 Page 44 D302K 3+12


SCR A Silicon Controlled Rectifier (SCR) is anelectrical device with three connections,anode, cathode, and gate. It will allow currentto flow in only one direction and will only doso after receiving a signal on the gate lead.SCR’s are used to change AC to DC and tocontrol the output to a load such as a weldingarc.

K

A

G

SHUNT A precision low-value resistor typically usedto supply a small voltage to drive anammeter. SHUNT

SNUBBER A device used to absorb voltage spikes,sometimes found connected across thepoints of a relay. SN1

SPARK GAP The arrangement of two electrodes betweenwhich a discharge of electricity will occur.Typically used to produce “ high frequency”which can be used for arc starting when TIGwelding.

G

STABILIZER/REACTOR

When placed in a DC circuit, the inductor orstabilizer as it is usually called, will opposeany change in existing current. It is thereforewidely used to “stabilize” the welding arc.When the inductor is placed in an AC circuit itis referred to as a reactor where it now actsto restrict the flow of current. A “tappedreactor” is used to create current ranges forwelding.

Z1

L1

SWITCH A mechanical device that completes orbreaks the path of the current or sends it overa different path.

SPDTSPST

A multi-pole switch will use dashed lines toconnect poles.

SPST = Single Pole Single ThrowSPDT = Single Pole Double ThrowDPST = Double Pole Single ThrowDPDT = Double Pole Double Throw

DPDTDPST

MOMENTARYSWITCH

A switch that “springs back” to its originalposition. S1

LIMIT SWITCH A switch mounted in the path of a movingobject and actuated by its passage. NRM OPEN NRM

CLOSEDS1S1

PUSH BUTTONSWITCH

A switch in which a button must bedepressed each time the contacts are to beopened or closed.

NRMOPEN

NRMCLOSED

PB1 PB1

ROTARY SWITCH A switch in which its shaft must be rotated toactuate the contacts.

S1 S1

TM-4424 Page 45D302K 3+12


PRESSURESWITCH

A change in the pressure of a gas or liquidwill actuate this switch.

OPENSON

INCREASE

CLOSESON

INCREASE

S1 S1

TEMPERATURESWITCH

Typically used to protect engines, this switchis actuated by heat.

OPENSON

INCREASE

S1

CLOSESON

INCREASE

S1

WATER FLOWSWITCH

A switch that is actuated by the flow of aliquid. Typically used to protect“water-cooled” torches.

OPENSON

INCREASE

S1

CLOSESON

INCREASE

S1

TERMINALASSEMBLY

A connection point for primary power and thejumper links that are used to match the inputvoltage to the machine. Usually, the terminalassembly is marked with the letters “TE”, butthe electrical symbol looks identical to astandard terminal strip.

TE1

TE1

TERMINAL STRIP An insulated connection point for wires. Theyare used for the ease of making multipleconnections and can be a convenient pointfor making electrical checks whentroubleshooting. (Notice the “jumper link”connecting terminals A and B together.)

A B C D E1T

42 42 104 105 74

104 105

THERMISTOR A thermally sensitive resistor. There are twotypes of thermistor, PTC (PositiveTemperature Coefficient) and NTC (NegativeTemperature Coefficient). A PTC thermistor’sresistance will increase as the temperaturegoes up, where as an NTC thermistor’sresistance will decrease as the temperaturegoes up. Primarily used for “Fan on Demand”and “Thermal Shutdown” circuits.

RT1

TH1

OR

THERMOSTAT,NORMALLY OPENAND NORMALLYCLOSED

This is a switch that closes its normally opencontacts (or opens its normally closedcontacts) when a preset temperature isreached. When the temperature goes backdown, it will reset itself. Uses of thesedevices include turning on a fan motor whenneeded and shutting off the output of awelding power source if it is overheating.

NRM OPEN NRM CLOSED

TP1TP1

TRANSISTOR Most commonly used as an electronic switch.There are two basic types, PNP and NPN.This refers to their internal design, whichdetermines current flow direction.

Q1 Q1

B

C

E

B

C

ENPN PNP

TM-4424 Page 46 D302K 3+12


TRANSFORMER A device that changes AC voltage from onemagnitude to another. Typically used toreduce high primary voltages to lowerwelding voltages.

T1

T1

T1

IRONCORE

AIRCORE

FERRITECORE

TRIAC An electronic AC switch. It is turned on by agate signal similar to an SCR. Q1

TWISTED WIRE Wires are twisted to prevent “electrical noise”from interfering with the circuit. A goodexample is the red and white gate leadsgoing to an SCR. Typically, these wires aretwisted together to help prevent the SCRfrom misfiring.

RED

WHT

VARISTOR A protection device whose resistance isdependent on the voltage applied to it. Innormal operation it has a high resistance;however, a surge of voltage (voltage spike)will cause its resistance to go way down andabsorb the spike. These devices are mostoften found in rectifying circuits, where theyare used to protect the diodes.

VR1

WIRES WITHCONNECTION

When lines (wires) cross on a circuit diagramand there is a “black dot”, this means that thetwo wires are electrically connected together.The method of connection (bolted, frictionlugs, etc.) is not indicated with this symbol.However, a “white dot” indicates that themethod of connection is a terminal strip. Ofcourse, no dot means no connection.

TM-4424 Page 47D302K 3+12

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

TM-4424 Page 48 D302K 3+12

SECTION 10 − TROUBLESHOOTING

10-1. Troubleshooting Tables

� See Section 10-2 for test points andvalues and Section 14 and followingfor parts location.

� Use MILLER Testing Booklet (PartNo. 150 853) when servicing thisunit.

Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection 7-10).

Note

A. Welding

Trouble Remedy

No weld output; generator power outputokay at ac receptacles.

Place Process/Contactor switch R1 in a Weld Terminals Always On position, or place switch in a RemoteOn/Off Switch Required position and turn remote contactor on (see Section 4-10).

Reset circuit breaker CB7 or CB8 (see Section 7-9). Check for faulty remote device connected to RC13or RC14.

Check and secure connections to Remote Control receptacle RC13 or RC14 (see Section 4-9 or 4-10).

Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms ±10%.Replace R2 if necessary.

Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for properconnections. Replace Z1 if necessary.

Check Voltmeter/Ammeter help displays (see Section 7-10).

No weld output, or generator power out-put at ac receptacles.

Disconnect equipment from generator power receptacles during start-up.

Reset circuit breaker CB3 (see Section 7-9).

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Checkrotor and brushes before replacing PC3.)


Clean slip rings, and install new brushes if necessary (see Section 10-13).

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-essary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator ifnecessary.

Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 10-9).(If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotorand brushes before replacing PC3.)

Erratic weld output. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor ifnecessary.

High weld output. Repair or replace remote control device.

Check hall device HD1, and replace if necessary (see Section 10-2).

TM-4424 Page 49D302K 3+12

Trouble Remedy

Check main control board PC1 and connections, and replace PC1 if necessary.

Low weld output. Check engine speed, and adjust if necessary.

Increase Voltage/Amperage Adjust control R2 setting.

Check fuse F1, and replace if open (see Section 7-9).

Repair or replace remote control device.


Low open-circuit voltage. Check engine speed, and adjust if necessary.

Check main control board PC1 and connections, and replace PC1 if necessary.


Check SCR’s in main rectifier, and replace if necessary. If any SCR’s are replaced, check capacitorsC1 through C9 for a short or open, and check for proper connections. Replace C1 through C9 if necessary.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC13 or RC14 (see Section 4-9or 4-10).

No 24 volt or 115 volt ac output at Re-mote receptacle RC14.

Reset circuit breaker CB7 (24 volt) or CB8 (115 volt) (see Section 7-9).

Check filter board PC6, and replace if necessary.

B. Generator Power

Trouble Remedy

No generator power output at ac recep-tacles; weld output okay.

Reset receptacle circuit breakers (see Section 6-1).

Check resistance of generator power windings between leads 91 and 92. Replace stator if necessary.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3 (see Section 10-9). (If PC3 senses an overload condition (shorted rotor), it protects itself by stoppingweld output. Check rotor and brushes before replacing PC3.)



Clean slip rings, and install new brushes if necessary (see Section 10-13).


Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator ifnecessary.


High output at generator power acreceptacles.


Low output at generator power ac receptacles.

Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3 (see Section 10-9). (If PC3 senses an overload condition (shorted rotor), it protects itself by stoppingweld output. Check rotor and brushes before replacing PC3.)

TM-4424 Page 50 D302K 3+12

C. Engine

Trouble Remedy

Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 7-9).Check engine wiring harness and components.


Check engine wiring harness plug connections.

Check continuity of Engine Start/Preheat switch S1, and replace if necessary.

Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.

Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and conditionof contacts. Replace CR1 if necessary.

Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. ReplaceFS1 if necessary.


Check fuel pump according to engine manual.

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Start/Preheat switch S1 (see Section 5-1).

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier forfuel information.

Use correct grade oil for cold weather (see Section 7-3).

Check continuity of Start/Preheat switch S1, and replace if necessary.

Check glow plug for proper operation, and replace if necessary.

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolanttemperature is too high (see Section 4-6).

Reset circuit breaker CB1 and/or CB2 (see Section 7-9). Check engine alternator, engine harness,fuel solenoid FS1, and the fuel pump.

Check continuity of Start/Preheat switch S1, and replace if necessary.

Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and conditionof contacts. Replace CR1 if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. ReplaceFS1 if necessary.


Check fuel pump according to engine manual.

Check engine wiring harness and plug connections.

See engine manual.

Engine slowly stopped and cannot berestarted.

Check fuel level.

Check engine air and fuel filters (see Sections 7-4 and 7-8).

See engine manual.

TM-4424 Page 51D302K 3+12

Trouble Remedy

Battery discharges between uses. Turn Start/Preheat switch S1 off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine uses oil during run-in period;wetstacking occurs.

Dry engine according to run-in procedure (see Section 13).

Notes

TM-4424 Page 52 D302K 3+12

10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)

I1

V6,

V7,R7

R6

Enginecontrol

relay CR1

See Section 10-9for PC3 data

V1,R1

V2,R2

V4,R4

V5,R5

V8,R8

V9,R9

R13

V10,R10

V11,R12

R11

V23

V24

V25

V26

E

V3,R3

See Section10-11 for PC2

data

V12,R13

TM-4424 Page 53D302K 3+12

See Section 10-4for waveforms

A,B,C,D,E

218 546-C

See Section10-5 for

PC6 data

See Section4-10 for RC14information

V13 V14 V15 V16

V17,A,C

V18, B,D

V20

EE EE

E E E E V21V22 V19

TM-4424 Page 54 D302K 3+12

10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)

Voltage Readings

a) Tolerance − ±10% unless specified

b) Condition − 70°F (21°C); cold machine(no warm-up); no load; weld/power rpmunless noted

c) Reference − single arrow: reference tocircuit common (lead 42); doublearrow: reference to points indicated

d) Process/Contactor switch R1 in WeldTerminals Always On − Stick (Dig-B)position unless noted

e) Wiring Connections − see Section 12

V1 120 − 124 volts ac

V2 120 − 124 volts ac

V3 240 − 248 volts ac

V4 158 volts ac

V5 24 volts ac

V6 46 volts ac

V7 46 volts ac

V8 46 volts ac

V9 + 61 volts dc

V10 +12 volts dc

V11 +12 volts dc while cranking engine

V12 +12 volts dc while cranking and runningengine

V13 0 to +5 volts dc from Weld TerminalsAlways On−Wire position to Remote−Wireposition of Process Contactor switch R1 (in0.45 volt increments)

V14 +5 volts dc

V15 0 to +5 volts dc from min to max ofVoltage/Amperage control R2

V16 +5 volts dc

V17 +41 volts dc with Process/Contactor switchR1 in Weld Terminals Always On − Stickposition; +20 volts dc with R1 in TIGposition

V18 14 to +40 volts dc with Process/Contactorswitch R1 in Weld Terminals AlwaysOn−Wire position

V19 Circuit common

V20 1 volt dc per 100 amperes of weld output

V21 − 15 volts dc

V22 +15 volts dc

V23 +12 volts dc

V24 +12 volts dc input with Start/Preheat switchS1 in Start position

V25 +12 volts dc input with Start/Preheat switchS1 in Start or Run position

V26 Ground path for CR1:Normal operation: 0 volts dcFault shutdown: +12 volts dc

Test Equipment Needed:

Amperage Readings

a) Tolerance − ±5% unless specified

b) Condition − 70°F (21°C); coldmachine (no warm-up); no load;weld/power rpm unless noted

c) Process/Contactor switch R1 inWeld Terminals Always On − Stick(Dig-B) position unless noted

I1 3.1 amps dc 4.6 amps at 20 volt, 200 amp load

Resistance Values

a) Tolerance − ±10% unlessspecified

b) Condition − 70°F (21°C); coldmachine (no warm-up)

c) Wiring Connections − seeSection 12

d) Stop engine before checkingresistance

R1 thru R8 Less than 1 ohmR9 22 ohmsR10 14.2 ohmsR11 Empty fuel tank: 250 ohms

Full tank: 0 ohmsR12 1 ohmR13 15.5 ohms

TM-4424 Page 55D302K 3+12

10-4. Waveforms For Sections 10-2

2 ms 50 V

A. CC/DC Open-Circuit Voltage, Process/Con-tactor Switch R1 In Weld Terminals Always On− Stick (Dig B) Position, Voltage/AmperageControl R2 At Max

2 ms 20 V

B. CV/DC Open-Circuit Voltage, Process/Con-tactor Switch R1 In Weld Terminals AlwaysOn − Wire Position, Voltage/Amperage Con-trol R2 At Max


gnd gnd

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

E. SCR Gate Pulses w/Respect To Cathode At NoLoad, Process/Contactor Switch R1 In WeldTerminals Always On − Stick (Dig B) Position,Voltage/Amperage Control R2 At Max

2 ms 50 V

gnd

C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro-cess/Contactor Switch R1 In Weld TerminalsAlways On − Stick (Dig B) Position, (ResistiveLoad)

D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-cess/Contactor Switch R1 In Weld TerminalsAlways On − Wire Position, (Resistive Load)

2 ms 20 V

gnd

5 ms 2 V

gnd

TM-4424 Page 56 D302K 3+12

10-5. Filter Board PC6 Testing Information

803 816 / 217 008

� Stop engine.

See Section 10-6 for specific val-ues during testing. Voltage read-ings tolerance ±10%.

1 Filter Board PC6

2 Receptacle RC2


1

2

TM-4424 Page 57D302K 3+12

10-6. Filter Board PC6 Test Point Values

PC6 Voltage Readings


b) Reference − to circuit common(lead 42) unless noted

c) Condition − no load; weld/pow-er rpm unless noted

d) Process/Contactor switch S6in Weld Terminals Always On −Stick position

Receptacle Pin Value

RC2 1 24 volt ac input with respect to pin RC2-5

2 Not used on this model

3 115 volts ac input with respect to pin RC2-5

4 Voltage feedback: 1 volt dc per 10 arc volts

5 Circuit common for 24 and 115 volt ac contactor control circuits

6 Command reference: +10 volt dc input

7 Contactor control circuit: 24 volt ac input with respect to pin RC2-5 and closure on RC14 betweenpins A and B

8 Command common

9 Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperagecontrol

10 Current feedback: 1 volt dc per 100 arc amperes

RC3 1 Output to remote control: 0 to +10 volts dc

2 DC input command signal: 0 to +10 volts dc from min to max of remote control with voltage/amperagecontrol R2 at max

3 Circuit common

TM-4424 Page 58 D302K 3+12

10-7. Main Control Board PC1 Testing Information

803 816

� Stop engine.


1 Main Control Board PC1

2 Plug PLG6

3 Plug PLG7

4 Plug PLG11


14

2

3

TM-4424 Page 59D302K 3+12

10-8. Main Control Board PC1 Test Point Values





d) Process/Contactor switch R1in Weld Terminals Always On −Stick position


PLG6 A1 Serial data line

A2 +5 volts dc output

A3 CV weld feedback with respect to pin PLG6-B3: same as OCV or load voltage

B2 Command signal input: 0 to +5 volts dc input from min to max of Voltage/Amperage control R2

B3 Voltage feedback reference

C1 Serial data line

C2 Circuit common for Voltage/Amperage control R2

C3 CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage

D2 Frequency to voltage signal: +10 volts dc input at 1860 rpm

D3 Not used on this model

E2 Synchronization signal

E3 Power supply input: +15 volts dc

F1 Not used on this model

F2 Voltage feedback: 1 volt dc per 10 arc volts

F3 Power supply input: −15 volts dc

G1 Not used on this model

G2 Command reference: +10 volt dc input

G3 Shutoff command output (field current); normal condition: 0 volts dc, fault condition: 0.7 volts dc

H1 Not used on this model

H2 Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperagecontrol

H3 Circuit common

J1 Not used on this model

J3 +10 volts dc output

K1 +5 volts dc output

K3 24 volts ac input

PLG7 A1 0 to +5 volts dc from Weld Terminals Always On−Wire position to Remote−Wire position of ProcessContactor switch R1 (in 0.45 volt increments)

A2 1 volt dc input per 100 amperes of weld output with respect to pin PLG7-C2

B1 Circuit common for Process/Contactor switch R1

B2 +15 volts dc output with respect to pin PLG7-C2

B3 Contactor control circuit: 24 volt ac input with respect to circuit common and closure on RC14 be-tween pins A and B

C1 +5 volts dc output

C2 Circuit common

C3 SCR fault signal; +5 volts dc output if any SCR fails

TM-4424 Page 60 D302K 3+12

Receptacle ValuePin

D1 +2 volts dc input at 77° F

D2 −15 volts dc with respect to pin PLG7-C2

E1 +13 volts dc input

F1 Command common

F2 Weld idle control signal: 0 volts dc output when welding; 3.5 volts dc input when not welding

F3 Current feedback: 0 volts dc input per 100 arc amperes

PLG11 A1 Gate Pulse to SCR1 with respect to pin PLG11-A2

A2 Reference for gate pulse to SCR1

A3 Gate Pulse to SCR2 with respect to pin PLG11-B3

B1 Reference for gate pulse to SCR3

B2 Gate Pulse to SCR3 with respect to pin PLG11-B1

B3 Gate Pulse to SCR2 with respect to pin PLG11-A3

C1 Gate Pulse to SCR4 with respect to pin PLG11-C2

C2 Reference for gate pulse to SCR4

C3 Reference for gate pulse to SCR5

D1 Reference for gate pulse to SCR6

D2 Gate Pulse to SCR6 with respect to pin PLG11-D1

D3 Gate Pulse to SCR5 with respect to pin PLG11-C3

E1 Gate Pulse to SCR7 with respect to pin PLG11-E2

E2 Reference for gate pulse to SCR7

E3 Gate Pulse to SCR8 with respect to pin PLG11-F3

F1 Reference for gate pulse to SCR9

F2 Gate Pulse to SCR9 with respect to pin PLG11-F1

F3 Reference for gate pulse to SCR8

TM-4424 Page 61D302K 3+12

10-9. Voltage Regulator Board PC3 Testing Information

803 816

� Stop engine.


1 Voltage Regulator Board PC3

2 Receptacle RC1

3 Receptacle RC2


1

2

3

TM-4424 Page 62 D302K 3+12

10-10.Voltage Regulator Board PC3 Test Point Values







RC1 1 14 volts dc input with respect to pin RC1-3

2 +13 volts dc output

3 Circuit common

4 Circuit common

5 Power supply output: +15 volts dc

6 Power supply output: −15 volts dc

7 +10 volts dc input

8 Shutoff command input (field current): normal condition: 0 volts dc, fault condition: 0.7 volts dc

9 Frequency to voltage signal: +10 volts dc output at 1860 rpm

10 SCR fault signal; +5 volts dc input if SCR fails

11 Synchronization signal

12 Not used

RC2 1 120 volts ac input with respect to pin RC1-3


3 Not used

4 Not used


6 +61 volts dc with respect to pin RC2-7

7 +61 volts dc with respect to pin RC2-6

8 158 volts ac with respect to pin RC2-5

9 Not used

10 Not used

11 Not used

12 Not used

TM-4424 Page 63D302K 3+12

10-11. Meter Display Board PC2 Testing Information

803 816 / 214 536

� Stop engine.


1 Meter Display Board PC2


1

10-12.Meter Display Board PC2 Test Point Values







RC1 1 +12 volts dc input with respect to pin RC1-2

2 Circuit common

3 Serial data line

4 Serial data line

TM-4424 Page 64 D302K 3+12

10-13.Replacing Brushes And Cleaning Slip Rings

Ref. 803 817 / Ref. 803 686

Tools Needed:


1 Brush Holder Bracket

Remove brush holder bracket.Keep hardware for reinstallation.

2 Brush Holder

3 Brush With Spring

4 Brush Holder Cap

5 Brush Holder Retaining Bar

Mark and disconnect leads at capsand remove retaining bar. Unscrewcaps and remove brushes frombracket.

Replace brushes if damaged, or ifbrush is at or near minimum length.

6 Slip Rings

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

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

� Stop engine.

Install brushes, caps, bar, bracket,and brush leads. Tighten brackethardware.

1

5/16 in (8 mm)Minimum Length

9/16 in (14.3 mm)New Length

ReplaceDamaged Brushes

5

23

4

6

TM-4424 Page 65D302K 3+12

10-14.Checking Unit Output After Servicing

� Also use output waveforms tocheck unit output after servic-ing (see Section 10-4).

Check engine speeds, and adjust ifnecessary (see Section 7-7).

Place Process/Contactor switchR1 in Weld Terminals Always Hot −Stick position.

1 AC Receptacles GFCI1,GFCI2, RC11

2 CC (Stick) And CV (Wire)Weld Output Terminals

3 Work Weld Output Terminal

Start engine and run at weld/powerspeed (1880 rpm).

Check voltage at each receptacle.With no load applied, there shouldbe 126 to 130 volts ac present atGFCI1 and GFCI2, and 252 to 260volts ac at RC11.

If correct voltage is not present, re-peat troubleshooting procedures inSection 10-1.

Check open-circuit voltage acrossweld output terminals according toSection 10-2. If correct voltages arenot present, repeat troubleshootingprocedures in Section 10-1.

� Stop engine.

Allow engine to cool, and then com-plete pre-operational checks intable.

Pre-Operational Checks

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Check fuel and oil (see Section 4-7).

Check and correct any fluid leaks.

Clean weld output and battery terminals. Tighten connections.

Clean outside of entire unit.

Tools Needed:Test Equipment Needed:

1

2

3

803 816

TM-4424 Page 66 D300K 3+12

SECTION 11 − DISASSEMBLY AND REASSEMBLY

11-1. Disassembly Of Unit

� Stop engine and let cool. Dis-connect battery negative (−)cable.

Use Section 10-1 to determine if troubleis in stator, rotor, engine or combinationof these components.

1 Engine Manifold Screw

2 Generator Mounting Screws

3 Engine Mounting Screw

4 Engine Lifting Eyes

Remove side panels, covers, anddoors. Retain all hardware.

Drain radiator according to Section 7-6and engine manual. Disconnect hosesat radiator.

Remove rear upright, right fan guard,and radiator assembly.

Disconnect flexible exhaust pipe at en-gine manifold.

Disconnect fuel line at engine.

� To aid in reassembly, mark leadsbefore disconnecting. See lead listsummary in Section 12 for connec-tion information.

Disconnect:

� generator cables from rectifier as-sembly

� generator power leads from termi-nal strip TE1

� engine wiring harness at in-lineconnector

� engine ground strap from base.

Use a hoist to evenly lift and removeengine/generator assembly.

Go to Section 11-2.

2

Remove brushesbefore removingendbell or rotor.

803 818

1

3

4

TM-4424 Page 67D300K 3+12

11-2. Disassembly Of Generator

803 686

� Do not damage stator or rotor win-dings during this procedure.

� Use hoist and lifting strap to carefullyremove generator components.

1 Brushes

2 Stator

3 Endbell

4 Rotor

5 Stud

Remove brushes from brushholder assemblybefore disassembling generator.

Remove engine and rotor by removing nutsfrom studs and separating stator from engineadapter. With engine properly supported, re-move hardware securing endbell to stator.

Reassembly Instructions:

Reinstall engine and generator parts asneeded using torque values in table.

Reinstall brushes in brushholder assembly.

Reinstall engine/generator assembly in unit.Reinstall mounting hardware and torque to 50ft lb (68 N.m).

Reconnect fuel line and exhaust pipe. Torqueengine manifold screws to 30 ft lb (41 N.m).

Reinstall radiator and rear upright. Refill ra-diator with coolant (see Section 7-6 and en-gine manual).

Reconnect all leads. Use cable ties to secureleads in existing wiring harness and awayfrom moving and hot parts.

Reconnect negative (−) battery cable. Rein-stall cover, panels, and doors.

A 20 ft lb (27 N.m)

B 10 ft lb (14 N.m)

C 60 in lb (7 N.m)

D 30 ft lb ( 41N.m)

Torques:

4

A

5

2

3

B

14

1C

D

TM-4424 Page 68 D300K 3+12

11-3. Replacing Rectifier SCR Modules

� Stop engine and let cool. Dis-connect battery negative (−)cable.

� Be sure to follow torque specifica-tions in table when installing andconnecting SCR module. Retorquemounting hardware after fourhours.

1 Rectifier Assembly

2 SCR Module

3 SCR Connection Screw

4 SCR Mounting Screw

Remove left side panel. Remove rectifi-er assembly screws and slowly tilt as-sembly out.

Remove defective SCR module.

Clean mounting surface where modulewill be installed

Apply a thin layer of supplied heat sinkcompound to mounting surface ofmodule.

Install new SCR module. Follow torquespecifications in table when installingpart. Remember to re-torque hard-ware as specified.

Remove protective foam from SCR ter-minals (if applicable) before connectingleads.

SCR Module Torques:

SCR Mounting Screw SCR Connection Screw Terminal

45 in lb, ±5 in lb(5 N⋅m, ±0.5 N⋅m)

After four hours re-torque to45 in lb, ±5 in lb

(5 N⋅m, ±0.5 N⋅m)

45 in lb, ±5 in lb(5 N⋅m, ±0.5 N⋅m)

803 703

4

31 2

TM-4424 Page 69D302K 3+12

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 insidemachine case or contact distributor for more information.

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

Model Serial Or Style Number CircuitDiagram

WiringDiagram

D302K 3+10 CC/CV Models LE185330 and following 218 546-C See Table 12-1

Circuit Board PC6(HF Filter Board)

LE185330 and following 217 005-A

Circuit Board PC2(Meter Display)

LE185330 and following 214 535-A

Notes

Over 80,000 trained

since 1930!400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Start Your Professional

Welding Career Now!

TM-4424 Page 70 D302K 3+12

Figure 12-1. Circuit Diagram For D300K 3+12 Effective With Serial No. LE185330 And Following

TM-4424 Page 71D302K 3+12

218 546-C

TM-4424 Page 72 D302K 3+12

217 005-A

Figure 12-2. Circuit Board PC6 (HF Filter) Effective With Serial No. LE185330 And Following

TM-4424 Page 73D302K 3+12

214 535-A

Figure 12-3. Circuit Board PC2 (Meter Display) Effective With Serial No. LE185330 And Following

TM-4424 Page 74 D302K 3+12

Table 12-1. Lead List Summary For D300K 3+12 Models Eff w/LF065150 And Following

� Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).

Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-appliedgrease had been present.

Lead Connections Lead Connections

−−−− PLG1 TO G1 −−−− PLG1 TO G2 −−−− PLG1 TO K1 −−−− PLG1 TO K2 11A STATOR TO RECT. 16A PLG6 (A3) TO R−3 RIGHT 16A SCR’S CV (+) TO C10 (+) 16B SCR CV (+) TO R3 (RIGHT) 17A Z1 TO SCR’S CC (+) 18A Z1 (CV) TO CV OUTPUT STUD 19A PLG6 (C3) TO R−3 LEFT 19A Z1 (CC) TO CC OUTPUT STUD 19B Z1 TO R3 (LEFT) 21A STATOR TO RECT. 30A PLG6 (B3) TO R−3 CENTER 30A SCR’S (−) TO C10 (−) 30B C10 (−) TO NEG OUTPUT STUD 30B HEAT SINK (−) TO R3 (CENTER) 31A STATOR TO RECT. 40A CR1 (8) TO PLG5 (1) 40B CR1 (8) TO PLG9 (1) 41A STARTER TO CB1 (BATTERY) 42A GROUND STUD TO TE1 42A GROUND TERMINAL TO PLG9 (3) 42A S2 TO GROUND TERMINAL 42AA GFCI−1 (GRND) TO GROUND STUD ON POWER

PANEL 42AB GFCI−2 (GRND) TO GROUND STUD ON POWER

PANEL 42B GROUND TERMINAL TO PLG5 (2) 42B SR2 TO GROUND TERMINAL 42B TE1 TO BASE GROUND 42C FUEL PUMP TO GROUND TERMINAL 42C GR STUD POWER PANEL TO RC11 (GR) 42C PC6 TO FRT PANEL GROUND 42C PLG6 (J1) TO EXIT 42D FUEL SENDER GROUND TO GROUND TERMINAL42E FUEL SENDER GROUND TO PLG1 (8) 42F ENGINE BLOCK GROUND TO GROUND TERMINAL42G GROUND TERMINAL TO GROUND TERMINAL42TG T1−5 TO TE−1 42Y FRONT PANEL GROUND STUD TO TE1 43A AMP METER (+) TO ALT (B) 43B CB2 TO CB3 43C CB2 TO ALT (B) 43D S1 (30) TO AMMETER (+) 44A CB1 (AUX) TO AMP METER (−) 45A CB3 TO CR1 (6) 46A STARTER TO FS1 47A STARTER TO S1 (50) 47B S1 (50) TO PLG1 (6) 48B CB2 TO CR1 (2) 52A CR1 (4) TO SR1 52B SR1 TO S4 (WIPER) 53A S4 (NO) TO CR1 (O) 53B CR1 (O) TO BARE 53C SR2 TO FS1 53D S4 (NC) TO PLG1 (4) 53E SR2 TO FUEL PUMP 53F ALT (IG) TO BARE 53G SR2 TO BARE 53H SR2 TO BARE 54A CR1 (1) TO PLG1 (7) 55A S1 (17) TO S1 (19) 55B S1 (17) TO GLOW PLUG 55C S1 (19) TO SR1 56A PLG1 (2) TO S2 57A PLG1 (3) TO S3

70A PLG7 (F2) TO PC5 (J) 71A PLG1 (5) TO FUEL LEVEL SENDER 80 PC6 − EXIT 80A STATOR TO TE1 81A PLG6 (K3) TO CB8 81A STATOR TO CB8 84A GFCI−1 (H) TO CB6 84C PLG10 (3) TO #84 STATOR LEAD 85A GFCI−2 (H) TO CB4 87A PC6 − CB7 90A STATOR TO TE1 (C) 90A TE1 (C) TO RC11 (WB) 90C GFCI−1 (N) TO TE1 (C) 90D GFCI−1 (N) TO GFCI−2 (N) 91A STATOR TO TE1 (B) 91A TE1 (B) TO CB5 91B PLG10 (1) TO #91 STATOR LEAD 91B STATOR TO VR 91C STATOR TO CB7 92A STATOR TO TE1 (A) 92A TE1 (A) TO CB5 92B PLG10 (2) TO #92 STATOR LEAD 92B STATOR TO VR 94A CB5 TO RC11 (X) 94B CB5 TO CB6 95A CB5 TO RC11 (Y) 95B CB5 TO CB4 99C PLG10 (4) TO #99 STATOR LEAD 100A STATOR TO SPLICE (PC3) 100B PLG10 (5) TO STATOR 100A 101A STATOR TO FUSE 1 105A PLG10 (6) TO BRUSH 106A PLG6 (F3) TO PLG9 (6) 107A PLG6 (D2) TO PLG9 (9) 108A PLG10 (7) TO BRUSH 109A PLG6 (E3) TO PLG9 (5) 112A PLG6 (E2) TO PLG9 (11) 113A PLG6 (H3) TO PLG9 (4) 114A PLG10 (8) TO F1 117A PLG6 (G3) TO PLG9 (8) 120A PLG7 (E1) TO PLG9 (2) 121A PLG7 (C3) TO PLG9 (10) 130A PLG6 (J3) TO PLG9 (7) 132A PC6 − CB8 135A PLG6 (G2) TO PC6 (6) 135C RC13 (C) TO RC3 (1) 136A PLG7 (F1) TO PC6 (8) 136C RC13 (A) TO RC3 (3) 137A PLG6 (H2) TO PC6 (9) 140A PLG7 (F3) TO PC6 (10) 141A PLG6 (F2) TO PC6 (4) 148A PLG6 (D3) TO PC6 (2) 148C RC13 (B) TO RC3 (2) 150A PLG7 (B3) TO PC6 (7) 160A PLG7 (B1) TO PLG3 (4) 161A PLG7 (A1) TO PLG3 (5) 162A PLG6 (K1) TO PLG3 (6) 165A PLG6 (C2) TO PLG2 (1) 166A PLG6 (B2) TO PLG2 (2) 167A PLG6 (A2) TO PLG2 (3) 180A PLG6 (F1) TO EXIT 181A PLG6 (G1) TO EXIT 182A PLG6 (H1) TO EXIT 188A PLG7 (C1) TO PLG4 (1) 189A PLG7 (D1) TO PLG4 (2) 190A PLG6 (A1) TO PLG5 (3) 191A PLG6 (C1) TO PLG5 (4)

TM-4424 Page 75D302K 3+12

SECTION 13 − RUN-IN PROCEDURErun_in1 8/01

13-1. Wetstacking

� Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur.

1 Welding Generator

Run diesel engines near rated volt-age and current during run-in periodto properly seat piston rings andprevent wetstacking. See name-plate, rating label, or specificationssection in this manual to find ratedvoltage and current.

� Do not idle engine longer thannecessary. Piston rings seatfaster if engine runs at weld/power rpm, and the weldinggenerator is kept loaded duringrun-in.

2 Engine Exhaust Pipe

Wetstacking is unburned fuel andoil in the exhaust pipe and occursduring run-in if the engine is run toolong at light load or idle rpm.

If exhaust pipe is coated with a wet,black, tar-like substance, dry theengine using one of the followingrun-in procedures.

See the engine manual for addition-al engine run-in information.

2

1

TM-4424 Page 76 D302K 3+12

13-2. Run-In Procedure Using Load Bank

S-0683

� Stop engine.

� Do not touch hot exhaustpipe, engine parts, or loadbank/grid.

� Keep exhaust and pipe awayfrom flammables.


1 Load Bank

Turn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall receptacle or genera-tor auxiliary power receptacle.

2 Welding Generator

Place Voltage/Amperage control inminimum position, and Process/Contactor switch in Weld TerminalsAlways On − Stick position.

3 Weld CablesConnect load bank to generatorweld output terminals using propersize weld cables with correctconnectors. Observe correctpolarity.

Start engine and run for severalminutes.

Set load bank switches and thenadjust generator Voltage/Amper-age control so load equals ratedvoltage and current of generator(see nameplate, rating label, or thespecifications section in this manu-al).

Check generator and load bankmeters after first five minutes thenevery fifteen minutes to be suregenerator is loaded properly.

� Check oil level frequently dur-ing run-in; add oil if needed.

After one hour (minimum) placeVoltage/Amperage control in mini-mum position, then turn off loadbank to remove load. Run engineseveral minutes at no load.



Repeat procedure if wetstacking ispresent.

2

3

1

4

TM-4424 Page 77D302K 3+12

13-3. Run-In Procedure Using Resistance Grid

S-0684

� Stop engine.

� Do not touch hot exhaustpipe, engine parts, or loadbank/grid.

� Keep exhaust and pipe awayfrom flammables.


1 Resistance Grid

Use grid sized for generator ratedoutput.

Turn Off grid.

2 Welding Generator

Place Voltage/Amperage control inminimum position, and ProcessContactor switch in Weld TerminalsAlways On − Stick position.

3 Weld Cables

Connect grid to generator weldoutput terminals using proper sizeweld cables with correct connec-tors (polarity is not important).

4 Voltmeter

5 Clamp-On Ammeter

Connect voltmeter and ammeter asshown, if not provided on generator.

Start engine and run for severalminutes.

Set grid switches and then adjustgenerator Voltage/Amperage con-trol so load equals rated voltageand current of the generator (seenameplate, rating label, or the spec-ifications section in this manual).

Check generator and meters afterfirst five minutes then every fifteenminutes to be sure generator isloaded properly.

� Check oil level frequently dur-ing run-in; add oil if needed.

After one hour (minimum), placeVoltage/Amperage control in mini-mum position, then shut down gridto remove load. Run engine severalminutes at no load.



Repeat procedure if wetstacking ispresent.

1

3 5

+

4

2

6

TM-4424 Page 78 D302K 3+12

Notes

Eff w/LE185330 And FollowingFor OM-4424 (215 179) Revisions A Thru E

TM-4424B April 2005

Processes

Description

Air Carbon Arc (CAC-A) Cuttingand Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

TM-4424 Page 80 D302K 3+12

SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING

� Hardware is common and notavailable unless listed.

Wirng harnesses are listed atthe end of parts section.

1−Fig.14-3

2

7

3−Fig.14-5

4

6

8

9

5

1011

12

14

15

13

16

17

102

9293 18

19 2021

22

23

9091

83

81

80

79

78

84

85

86

87

8988

94

95

96

98 99

97−Fig.14-2

101

100

82

Figure 14-1. Main Assembly

Eff W/LE185330 And Following

TM-4424 Page 81D302K 3+12

803 748−C

53

71

7372

74

75

76

7770−Fig.14-4

68

6766

6564 63

62

53

5554

5657

5861

60

59

34

35 36

37

3839

30

4142

46

4748 49

43

50

51

52

4544

43

3132

33

30

2928

27

26

25

24

40

69


TM-4424 Page 82 D302K 3+12

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-1. Main Assembly

Quantity

1 Figure 14-3 Control Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 217070 Bracket, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 14-5 Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 214742 Capacitor Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213489 Bus Bar, Capacitor Bank Negative 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213490 Bus Bar, Capacitor Bank Positive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C10 163535 Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181853 Insulator, Screw (For Rectifier Mtg) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Z1 213929 Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192303 Angle, Mtg Stabilizer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 215522 Bracket, Vault 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +213547 Panel, Engine Side SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PC1 214769 Module, Main Control/Scr Gating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PC3 214770 Module, Voltage Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 213493 Upright, Center Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 189464 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 213501 Bracket, Fuel Pump/Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 218469 Filter, Fuel Spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 207721 Pump, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 *213858 Filter, Fuel In−line 5/16x5/16 Mic 125 −175 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 214753 Bracket, Holddown Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 213602 Gasket, Exhaust Outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 212620 Pipe, Exhaust Flexible Inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 183314 Clamp, Muffler 1.625 Dia U Pld 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 212604 Baffle, Air Lower Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 201528 Muffler, Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 212605 Pipe, Exhaust Blue Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 +213542 Cover, Top SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049525 Nut, 312−18 U−nut Multi−thread 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 189052 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 190198 Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 176104 Label, Warning Falling Equipment Can Cause Serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 202629 Cover, Radiator Access SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 214604 Pipe, Exhaust Elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 176230 Label, Hot Exhaust Parts Do Not Touch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 176103 Label, Use Diesel Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 213472 Keeper, Latch Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 213633 Bracket, Cover Top SS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 212624 Shroud Adapter, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 213503 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 +212607 Shroud, Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 212606 Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 212603 Baffle, Air Upper Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 +213544 Upright, Rear SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 220295 Bracket,Stiffener (Eff w/LE304607) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 190190 Tank, Coolant Recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 213502 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 176106 Label, Warning Moving Parts Can Cause Serious 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 217698 Label, Help Codes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 176108 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 176109 Label, Caution Using Ether To Aid Engine Etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 215269 Label, Diesel Engine Maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 190126 Latch, Paddle Series 20 (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 +213546 Door, Engine Access SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191626 Bumper, Door Engine Access 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 189975 Hinge, Door Access 180 Deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


TM-4424 Page 83D302K 3+12

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-1. Main Assembly (Continued)

Quantity

51 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 213545 Panel, Rocker SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 213266 Mount, Engine/Generator Flange Mtg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 197506 Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 213480 Bracket, Mtg Engine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 049026 Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Washer, Oil Drain (Order Thru Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199505 Hose Assy, Oil Drain 32.000 Lg (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 113854 Hose, Sae .500 Id X .780 Od Xcoil 2.6 Ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 176529 Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 165271 Valve, Oil Drain 3/8−18 Nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 212616 Hose, Radiator Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 218468 Belt, Alternator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 210790 Engine, Kubota Dsl Elec 1505 (1800) (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*218467 Filter, Oil Kubota V1505 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213244 Switch, Thermo Temp 230deg +/−5deg F Nc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 212615 Hose, Radiator Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 216811 Clip, Nut Retaining 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 197613 Air Cleaner, Intake 5.250 In (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197675 Dust Ejector, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *197676 Element, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197677 Cover Assy, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197678 Body, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦*197679 Element, Air Cleaner Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197829 Bracket, Mtg Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 212618 Hose, Air Intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 S3 221485 Switch, Pressure Oil 4psi No 1/8−28 Bspt (Eff w/LE341969) 1. . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 14-4 Generator Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 213461 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212623 Tank, Fuel (Includes Fuel Cap And Items Below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 189908 Valve, Drain Fuel 180 Deg Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 181572 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 124253 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 212611 Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 212610 Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 SENDER 213265 Sender, Fuel Gauge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211961 Hose, Sae .312 Id X .560 Od X 16.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213804 Hose, Sae .312 Id X .560 Od X 2.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191819 Hose, Sae .312 Id X .560 Od X 15.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145054 Hose, Sae .187 Id X .410 Od X 26.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 213465 Bolt, J Stl .312−18 X 7.250 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 213466 Bracket, Battery Holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 BATT 146237 Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 190206 Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 213668 Bracket, Mtg Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 200864 Label, Warning Do Not Weld On Base CE (Wordless) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 213458 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 213459 Crossmember, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 213460 Crossmember, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 213462 Pad, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


TM-4424 Page 84 D302K 3+12

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-1. Main Assembly (Continued)

Quantity

213670 Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 213463 Spacer/Snubber, Generator Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213600 Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213464 Bracket, Battery Locator (In Base − Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 213485 Support, Engine Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 213484 Support, Engine Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 213500 Brkt, Beam Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 213504 Tray, Reactor&Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213491 Insulator, Capacitor Bank (Applies To Reactor /Rectifier Tray) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213506 Bracket, Hold−Down Fuel Tank (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 +213543 Upright, Front SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 200795 Label, Warning General Precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 213541 Panel, Front Access SS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Figure 14-2 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 ♦105370 Xfmr, Current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 216347 Label, Rating Card Code (Provide Serial No. When Ordering) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 R3 213027 Resistor, WW Tap 300 W 40 Ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 TE1 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173734 Link, Jumper 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215326 Kit, Label (Includes Safety And Informational Labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.* Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


TM-4424 Page 85D302K 3+12



803 749

1

2

3

4

6

7

3938

8

9

11

1213

14

1516

17

18

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20

21

33

34

35

36

37

40

5

10

28

25

3130

32

24

23

22

29

2627

Figure 14-2. Panel, Front w/Components

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 97)

Quantity

1 097926 Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 072590 Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 190323 Boot, Circuit Breaker Clear Hex Nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 108864 Conn, Circ Ms Protective Cap Size 16−16s Metal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nameplate, Control (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PC6 217008 Circuit Card Assy, Connector/Receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CB7, CB8 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


TM-4424 Page 86 D302K 3+12

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-2. Panel, Front w/Components (Continued)

Quantity

10 RC3 214899 Receptacle, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 218556 Panel, Front Engine/Weld Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 214543 Enclosure, Circuit Card Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PC2 214660 Circuit Card Assy, Display W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 R1 214760 Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 R2 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 S4 021467 Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 S1 207720 Switch, Ignition 3 Position (Includes Knob) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 039047 Terminal, Pwr Output Red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 010381 Connector, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C13, 14, 15 128750 Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 209056 Cover, Receptacle W/Gasket 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 RC11 182954 Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nameplate, Generator Power (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 213509 Panel, Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 GFCI1, 2 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C11, C12 217054 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CB4, CB6 093996 Circuit Breaker, Man Reset 1p 20a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 CB5 203026 Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 GRD 083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 010915 Washer, Flat .257idx0.640odx.031t Brs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 601836 Nut, 250−20 .50hex .19h Brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Nameplate, Weld Terminal (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 181169 Spacer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 186621 Boot, Generic Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 180735 Washer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FUEL/HM 214768 Gauge, Fuel Elec/Hour Meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 021385 Boot, Toggle Switch Lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 AM 118060 Meter, Amp Dc 60−0−60 2.250 Dia High Profile Stainl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.



TM-4424 Page 87D302K 3+12



803 798

1

2

3

4

5

6

7

89

Figure 14-3. Control Panel

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-3. Control Panel (Figure 14-1 Item 1)

Quantity

1 220981 Bracket, Mtg Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CR1 199999 Relay, Encl 12vdc Dpst−no 30a 6pin Flange (Prior to LF065150) 1. . . . . . . . . . . . . . . . . . . 4 CR1 223669 Relay Assy (Eff w/LF065150) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F1 085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CB2, CB3 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




TM-4424 Page 88 D302K 3+12

803 771



2

31

4

5

6

7

8

9

10

11

1213

14

192018

1517

16

Figure 14-4. Generator

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-4. Generator (Figure 14-1 Item 70)

Quantity

1 ROTOR 212474 Rotor, Generator 4 Pole (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 192600 Fan, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 159918 Baffle, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 193515 Adapter, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 212641 Stud, Stl .375−16 1.625x 19.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STATOR 212470 Stator, Generator 4 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 160943 Endbell 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 167788 Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 218552 Brush, Assembly 2 Pole (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 047879 Bar, Retaining Brushholder 2 Brushes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 161306 Cap, Brushholder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 126984 Brush w/Spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 005614 Holder, Brush 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 125548 Holder, Brush Elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 158832 Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


*Recommended Spare Parts.♦Optional



TM-4424 Page 89D302K 3+12

803 685-A



1

2

3

6

4

5

9

8

10

7

Figure 14-5. Rectifier Assembly

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 14-5. Rectifier Assembly (Figure 14-1 Item 3)

Quantity

217081 Rectifier, Assembly (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 211984 Heat Sink 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MOD1,2,3 218296 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MOD4,5,6 218292 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 212602 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 212639 Bus Bar, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 212601 Insulator, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TH1 213930 Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C1−6 215611 Capacitor Assy 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 C7,8,9 048420 Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 217085 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181853 Insulator, Screw (For Mounting Rectifier) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



TM-4424 Page 90 D302K 3+12

Some wiring harness components (switches, relays, circuit breakers) are also referencedelsewhere in this parts list. Purchase components separately or as part of the associatedwiring harness.

Note

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Wiring Harnesses

Quantity

217141 Harness, Engine Kubota (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S4 199691 Switch, Tgl Spdt 6a 125vac On−none−mc Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2, CB3 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG1 214932 Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192168 Conn, Rect 250 1pin 1row Rcpt Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214934 Seal, Plug Univ 039 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217002 Harness, Weld Control (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG2 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG9 214951 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214934 Seal, Plug Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG6 193184 Conn, Rect Cinch 30 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG7 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG9 215261 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 215262 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215265 Conn, Deutsch Wedge Lock 12 Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215343 Seal, Plug Deutsch 12−16 Size 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217000 Cable, Lem 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215340 Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214933 Seal, Wire Univ 039 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214984 Harness, Rectifier CC/CV (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG11 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207716 Conn, Faston Mini Polarized 2 Skt G1k1 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207718 Conn, Faston Mini Polarized 2 Skt G2k2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217010 Harness, Receptacle Auxiliary Power (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB4, CB6 093996 Circuit Breaker, Man Reset 1p 20a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRINTED IN USA 1/04

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Contact the Delivering Carrier for:

For assistance in filing or settling claims,contact your distributor and/or equipmentmanufacturer’s Transportation Department.

Owner’s Record

File a claim for loss or damage duringshipment.

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