t4424b D302K 3 + 12 CC/CV DIESEL WELDER - Red-D-Arc

t4424b D302K 3 + 12 CC/CV DIESEL WELDER - Red-D-Arc
TM-4424B
April 2005
Eff. w/Serial Number LE185330 And
Following
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1.
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2.
Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3.
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4.
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1.
Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.
Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.
Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1.
Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.
Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3.
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4.
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5.
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6.
AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1.
Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2.
Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3.
Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4.
Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5.
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6.
Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7.
Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8.
Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9.
Connecting To Remote 3 Pin Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1.
Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2.
Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3.
Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4.
Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5.
Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1.
115 Volt And 230 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2.
Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3.
Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4.
Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5.
Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6.
Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7.
Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8.
Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9.
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
3
3
7
8
9
9
9
10
11
11
12
13
13
14
15
16
17
18
19
19
20
20
22
22
23
24
25
26
27
27
28
28
29
30
31
32
32
33
34
35
36
38
40
TABLE OF CONTENTS
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . . . . . . . . .
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Waveforms For Sections 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Voltage Regulator Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Voltage Regulator Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-14. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
48
52
54
55
56
57
58
59
61
62
63
63
64
65
66
66
67
68
69
75
75
76
77
80
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-4424E - 1/05, safety_rtm 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Y Only qualified persons should test, maintain, and repair this
unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
ENGINE EXHAUST GASES can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit unless the procedure specifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D Do not breathe exhaust fumes.
D Use in open, well-ventilated areas, or vent exhaust outside and away from any building air intakes.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
D
D
D
D
D Keep away from moving parts such as
fans, belts, and rotors.
D Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
Keep hands, hair, loose clothing, and tools away from moving parts.
Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator components.
Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
D302K 3+12
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connecting battery cables.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
TM-4424 Page 1
STEAM AND HOT COOLANT can burn.
TILTING OR TIPPING can cause injury.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Do not put any body part under unit while lifting.
D Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
D Be careful when working on stator and rotor assemblies.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
H.F. RADIATION can cause interference.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
D
FALLING UNIT can cause injury.
D Use equipment of adequate capacity to lift and
support unit and components.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Securely attach components to lifting equipment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
D Allow cooling period before servicing.
D Wear protective gloves and clothing when
working on a hot engine.
D Do not touch hot engine parts bare-handed.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
D
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
1-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-4424 Page 2
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 from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
D302K 3+12
SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
2
1
3
4
5
1
6
10
+ −
1
11
+
1
4
4
+
−
7
3
3
2
+
−
2
+
−
−
S-176 108
8
9
12
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away from
battery.
3 Sparks can cause battery
gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 Battery acid can burn skin. Do
not 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 negative
cable to dead battery − connect
instead to engine block.
11 Jumper cables − observe
polarity and make connections
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
3/96
shown.
1
1
2
2
3/96
S-176 106
1
2
1
2
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
4
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Ether will damage engine. Do
not use ether as a starting aid.
Read Owner’s Manual.
Use glow plugs for 10−25
seconds to aid starting in cold
weather.
6/02
D302K 3+12
TM-4424 Page 3
1
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
2
S-176 230
3/96
1
1
2
3
2
3
4
4
5
6
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Engine fuel plus flames or
sparks can cause fire.
Do not smoke while fueling or if
near fuel.
Stop engine before fueling.
Do not fuel a hot engine.
Use Diesel Fuel only.
6
3/96
1
1
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
serious injury and damage.
Use lifting eye to lift or move
unit
only.
Use
proper
equipment when lifting.
Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.
S-176 104
2
TM-4424 Page 4
3
4
3/96
D302K 3+12
1
1
2
2
3
4
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Fire hazard from leaking
engine fuel. Fire can result from
welding
on
base
at
non-designated areas causing
a possible fuel leak.
Fuel tank is located inside
base.
Do not weld on base of unit.
Weld only on supplied brackets
or bolt unit down.
5
3
4
1
1
2
3
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
3
D302K 3+12
TM-4424 Page 5
S-177 571
1
+
2
2
3
+
3
1
4
DIESEL
5
4
6
5
7
0 − 50 h Std.
200A
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
TM-4424 Page 6
D302K 3+12
2-2. Manufacturer’s Rating Label
219 870−D
D302K 3+12
TM-4424 Page 7
2-3. Symbols And Definitions
NOTE
A
Some symbols are found only on CE products.
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
(Preheat)
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Amperes
Time
3
V
h
Hours
Three Phase
Read Operator’s
Manual
Electrode
Connection
Work Connection
s
Seconds
G
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
I
Current
TM-4424 Page 8
Arc Force (Dig)
Single Phase
Do Not Switch
While Welding
Circuit Breaker
X
Contactor On
1
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
Lift-Arc TIG
D302K 3+12
SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld Output
Range
Rated Welding
Output
Maximum
OpenCircuit
Voltage
Generator Power
Rating
Engine
Fuel
Capacity
65
Single-Phase,
10 kVA/kW, 84 A,
120 V AC,
60 Hz
Kubota 1505 EBG1
Water-Cooled,
Water
Cooled,
Four-Cylinder,
20.2 HP Diesel Engine
11.5 gal
(43.5 L)
400 A, 23 Volts DC,
40% Duty Cycle
300 A, 32 Volts DC
60% Duty Cycle
20 − 410 A
CC/DC
250 A, 30 Volts DC
100% Duty cycle
400 A, 23 Volts DC,
30% Duty Cycle
CV/DC
300 A, 29 Volts DC
60% Duty Cycle
14 − 40 V
250 A, 26.5 Volts DC
100% Duty cycle
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
Width
G
32 in (813 mm)
35-3/4 in (908 mm)
(to top of lift eye)
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
26-1/4 in (667 mm)
(mtg. brackets turned in)
Y Do not move or operate unit where it could
tip.
28-3/4 in (730 mm)
(mtg. brackets turned out)
Depth
56 in (1422 mm)
A
56 in (1422 mm)
B
54 in (1372 mm)
C
52 in in (1321 mm)
D
2 in (51 mm)
E
26 in (660 mm)
F
7/8 in (22 mm)
G
27-3/4 in (705 mm)
H
9/16 in (14 mm) Dia.
4 Holes
Weight
No fuel: 1040 lb (471 kg)
A
B
C
30°
20°
H
Front Panel End
D
30°
20°
F
E
w/ fuel: 1139 lb (516 kg)
D302K 3+12
TM-4424 Page 9
3-3. Volt-Ampere Curves
A. Stick Mode
DC VOLTS
100
90
80
70
60
50
40
30
20
10
0
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
MIN
0
300
100
200
300
MAX
400
500
400
500
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
40
20
0
0
100
200
300
DC AMPERES
C. TIG Mode
100
DC VOLTS
80
60
40
20
0
MIN
0
300
100
200
300
MAX
400
500
DC AMPERES
217 517 / 217 516 / 217 518
TM-4424 Page 10
D302K 3+12
3-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
1.75
U.S. GAL/HR.
1.50
1.25
1.00
0.75
0.50
0.25
0.00
IDLE
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
217 509
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 250 Amperes
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
1000
WELD AMPERES
800
600
500
400
CC
CV
300
250
200
150
100
10
15
20
25
30
40
50 60
80
100
% DUTY CYCLE
217 515
D302K 3+12
TM-4424 Page 11
3-6. AC Generator Power Curve
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
20
40
60
80
AC AMPERES IN 240 V MODE
0
40
80
120
160
AC AMPERES IN 120 V MODE
217 519
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
TM-4424 Page 12
D302K 3+12
SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Y Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Movement
Y Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
Y If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
. See Section 4-2 for mounting information.
Grounding:
1
Location
2
3
OR
Equipment Grounding Terminal
(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insulated copper wire.
OR
Grounding
1
GND/PE
2
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
3
Y Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274
D302K 3+12
TM-4424 Page 13
4-2. Mounting Welding Generator
Y Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
Y Do not mount unit by supporting the base only at the
four
mounting brackets.
Use cross-supports to adequately support unit and prevent damage to base.
2
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brackets.
1
3
Inadequate support.
4
1/2 in Bolt And Washer
(Minimum − Not Supplied)
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Y Do not use flexible mounts.
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in
Ref install3 6/04 803 274 / 190 250-A / 803 231
TM-4424 Page 14
D302K 3+12
4-3. Installing Exhaust Pipe
Y Stop engine and let cool.
. Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
803 582 / Ref. 214 777-E
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12
TM-4424 Page 15
4-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection − Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Y Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Y Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
. When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
−
rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − 0886
TM-4424 Page 16
D302K 3+12
4-5. Connecting The Battery
. Close door after connecting battery.
Tools Needed:
1/2 in
Y Connect Negative (−) Cable Last.
+
−
Ref. 214 777-E / 803 581−D / S-0756-C
Notes
D302K 3+12
TM-4424 Page 17
4-6. Engine Prestart Checks
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Diesel
Capacity:
6 qt (5.7 L)
Coolant Recovery Tank
Hot Full
Cold Full
Full
803 581−D
. 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 if
oil pressure is too low or coolant temperature is too high.
. This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.
Fuel
Y Do not use gasoline. Gasoline will
damage engine.
The unit is shipped with enough fuel to prevent air from entering fuel system. Add fresh
diesel fuel before starting (see engine maintenance label for fuel specifications). Leave
filler neck empty to allow room for
expansion.
TM-4424 Page 18
Do not run out of fuel or air will enter fuel system and cause starting problems. See engine manual to bleed air from fuel system.
freeze to mixture if using the unit in temperatures below −34° F (−37° C).
Oil
Keep radiator and air intake clean and free
of dirt.
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34° F (−37° C). Add anti-
Y Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
. To improve cold weather starting:
Use Preheat switch (see Section 5-1).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 7-3).
D302K 3+12
4-7. Connecting To Weld Output Terminals
Y Stop engine.
1
Work (−) Weld Output Terminal
2
CV (Wire) Weld Output Terminal
3
CC (Stick/TIG) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode
holder cable to CC (Stick/TIG) terminal on
right and work cable to Negative (−) terminal
on left.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select type
of weld output (see Section 5-3).
MIG and FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP, connect wire feeder cable to CV (Wire) terminal on right and
work cable to Work/Negative (−) terminal on
left. Use Process/Contactor switch to select
type of weld output (see Section 5-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Tools Needed:
1
2
3
3/4 in
803 560 / 214 777-E
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not 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
400 ft
(105 m) (120 m)
Weld Output
Terminals
Y Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 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)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
10 − 100% Duty Cycle
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.
D302K 3+12
TM-4424 Page 19
4-9. Connecting To Remote 3 Pin Receptacle RC13
Socket
Socket Information
A
Remote control circuit common.
B
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage control at max.
C
Output to remote control: 0 to
+10 volts dc.
REMOTE
OUTPUT
CONTROL
803 580
4-10. Connecting To Remote 14 Receptacle RC14
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB8.
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG mode; 0 to +10
volts dc in Stick or TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
115 VOLTS AC
I
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB7.
J
Contact closure to I completes
115 volt ac contactor control
circuit.
F
Current feedback: 1 volt per
100 amperes.
OR
803 580
H
Voltage feedback: 1 volt per 10
arc volts.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 and 115
volt ac circuit.
*The remaining sockets are not used.
TM-4424 Page 20
D302K 3+12
Notes
Start Your Professional
Welding Career Now!
D302K 3+12
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
TM-4424 Page 21
SECTION 5 − OPERATING WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
7
8
9
10
11
12
2
6
1
4
5
3
Stop
214 777-E / 803 581−D
TM-4424 Page 22
D302K 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 glow
plug for cold weather operation.
Engine runs at weld/power speed continuously.
Turn switch to Preheat position to operate the
glow plug and heat the combustion chambers
before cranking engine (see starting instructions following).
2
Engine Shutdown Switch
Push switch down to stop engine.
3
Engine Stop Lever
Use lever to stop engine if Engine Shutdown
switch does not work.
. The Engine Stop lever shuts off the fuel
supply. However, the Engine Stop lever
will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
. If engine does not start, let engine come
to a complete stop before attempting restart.
Above 41 F (5 C): turn Start/Preheat switch
to Preheat position for 5 seconds and then
turn switch to Start position. Release Start/
Preheat switch when engine starts.
Below 41 F (5 C):
Turn Start/Preheat switch to Preheat position
for 15 seconds and then turn switch to Start.
Release Start/Preheat switch when engine
starts.
To Stop:
Push Engine Shutdown switch down to stop
engine.
D302K 3+12
Engine Gauges, Meters, And Lights
4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine
operating hours.
To check fuel level or engine hours when engine is not running, turn Start/Preheat switch
to Preheat position.
5 Engine Indicator Light
Light goes on and engine stops if engine temperature exceeds 230° F (110° C) or engine
oil 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).
Y Do not run engine until trouble is
fixed.
6 Battery Ammeter
Use gauge to check amperage output to the
battery. The gauge reads near 0 (zero) when
the engine is running. If gauge is at a negative
number, the battery is discharging.
Weld Controls
7 Remote 14 Pin Receptacle
8 Remote 3 Pin Receptacle
Use receptacles to connect remote controls,
wire feeders, and tools.
When a remote control is connected to a Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control connected to
that receptacle (see Sections 4-9, 4-10 and
5-5).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage settings.
If no remote control is connected to a Remote
receptacle, the front panel Voltage/Amperage
control adjusts voltage and amperage.
. If remote controls are connected to both
remote receptacles, remote amperage/
voltage control is only available through
the Remote 3 Pin receptacle. However,
the Remote 14 Pin receptacle still provides remote contactor control.
. If a remote device connected to Remote
Receptacle RC13 or RC14 is faulty or is
disconnected, the meters display Help 25
(see Section 7-10). Clear fault by stopping and restarting the unit or by turning
Process/Contactor switch to another
position.
9
Process/Contactor Switch
See Section 5-3 for Process/Contactor
switch information.
10 Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG 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 Remote position, control limits the remote amperage in Stick or TIG mode, but has no effect
in Wire (MIG) modes.
Weld Meters
. Weld meters also work in combination to
display troubleshooting help codes (see
Section 7-10).
11 DC Voltmeter
Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
To set voltage, turn contactor off and turn Process/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults
to preset voltage.
12 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
TM-4424 Page 23
5-3. Process/Contactor Switch
1
Process/Contactor Switch
Y Weld output terminals are energized when Process/Contactor
switch is in a Weld Terminals Always On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table below).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
“sticking” electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-4).
803 560 / 214 777−E
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Remote On/Off Switch Required −TIG LIft Arc
GTAW With HF Unit, Pulsing Device, Or Remote Control
At Remote 14 Receptacle
Remote On/Off Switch
Required − Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Remote On/Off Switch
Required − CV Feeder
Using Remote
MIG (GMAW)
w/Constant Speed Feeder
At Remote 14 Receptacle
Weld Terminals Always On − Wire
MIG (GMAW)
w/Voltage Sensing Feeder
Electrode Hot
Weld Terminals Always On − Stick
Stick (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 24
D302K 3+12
5-4. Lift-Arc™ Start Procedure
Lift-Arc t TIG
With Lift-Arct TIG selected, start
arc as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point.
Hold
electrode
to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or being contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12
TM-4424 Page 25
5-5. Remote Voltage/Amperage Control
1
1
2
Remote 3 Pin Receptacle
RC13
Remote 14 Pin Receptacle
RC14
Connect optional remote control to
either RC13 or RC14 (see Sections
4-9 and 4-10 and).
2
In Example:
Process = Stick (Using Remote On/Off)
Min = 20 A DC
Max = 205 A DC
Example: Combination Remote Amperage Control (Stick)
OR
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC13
Or RC14
Set Remote Process (Only If
Remote On/Off Control Is
Desired)
Set V/A Control
Mid-Range:
About 205A
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Min = 20 A DC
Max = About 205 A DC
Example: Combination Remote Amperage Control (TIG)
OR
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC13
Or RC14
TM-4424 Page 26
Set Remote Process (Only If
Remote On/Off Control Is
Desired)
Set V/A Control
Mid-Range:
About 205 A
Adjust Optional Remote Control
Ref. 214 777-E / 803 580
D302K 3+12
SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. 115 Volt And 230 Volt Receptacles
1
2
3
4
5
6
214 777-D
1
115 V 20 A AC GFCI
Receptacle GFCI1
2
115 V 20 A AC GFCI
Receptacle GFCI2
3
230 V 50 A AC
Receptacle RC11
GFCI1 and GFCI2 supply 60 Hz singlephase power at weld/power speed.
Maximum output from GFCI1 or GFCI2 is
2.4 kVA/kW.
If a ground fault is detected, GFCI Reset
button pops out and receptacle does not
work. Check for faulty equipment plugged
in receptacle. Press button to reset GFCI
receptacle.
D302K 3+12
. At least once a month, run engine at
weld/power speed and press test button to verify GFCI is working properly.
RC11 supplies 60 Hz single-phase power
at weld/power speed. Maximum output
from RC11 is 10 kVA/kW.
4
Circuit Breaker CB4
5
Circuit Breaker CB6
6
Circuit Breaker CB5
CB4 protects GFCI2 and CB6 protects
GFCI1 from overload. If a circuit breaker
opens, the receptacle does not work. Press
button to reset breaker.
Circuit breaker CB5 protects receptacles
GFCI, GFCI2, RC11 and the generator
winding from overload. If CB5 opens, the
receptacles do not work. Place CB5 switch
in On position to reset circuit breaker.
. Generator power decreases as weld
output increases.
Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator.
EXAMPLE: If 15 A is drawn from each 115
V receptacle , only 26 A is available at the
230 V receptacle:
2 x (115 V x 15 A) + (230 V x 26 A) =
10.0 kVA/kW
TM-4424 Page 27
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Y Stop engine before maintaining.
Recycle engine
fluids.
. See
Engine Manual and Maintenance
Label for important start-up, service,
and storage information. Service unit
more often if used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
Every 8 h
Coolant
Full
Wipe
Up
Spills.
Check Fluid
Levels. See
Section 4-6.
OIL
Full
FUEL
WATER
Drain Water
From Fuel
System.
Every 50 h
Clean And
Tighten
Weld
Terminals.
Clean Air Filter.
See Section 7-4.
Every 100 h
Clean And
Tighten
Battery
Connections.
Check air cleaner
hoses for cracks
and loose clamps.
Every 250 h
Replace
Unreadable
Labels.
Change Oil. See
Section 7-8.
TM-4424 Page 28
1/2 in.
(13 mm)
Change Oil Filter.
See Section 7-8.
Check Belt
Tension.
Check And
Clean Spark
Arrestor. See
Section 7-5.
D302K 3+12
Every 500 h
Repair Or
Replace
Damaged
Cables.
FUEL
Change Fuel
Filters. See
Section 7-8.
Check Radiator
Fluid Level. See
Section 4-6.
SLUDGE
Drain Sludge
From Fuel
Tank. See
Section 7-8.
Every 1000 h
OR
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Service Welding
Generator Brushes And
Slip Rings. Service More
Often In Dirty Conditions.*
Check
Valve
Clearance.*
Every 2000 h
Clean/Set Injectors.*
7-2. Checking Generator Brushes
Y Stop engine and let cool.
1
Generator Brush With Spring
Mark and disconnect leads at brush holder cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.
5/16 in. (8 mm)
Minimum Length
9/16 in. (14.3 mm)
New Length
Replace
Damaged Brushes
1
Ref 214 777−F / S−0233−A
D302K 3+12
TM-4424 Page 29
7-3. Maintenance Label
TM-4424 Page 30
D302K 3+12
7-4. Servicing Air Cleaner
Y Stop engine.
1
2
3
Y Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
. The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Y Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 214 777-D
D302K 3+12
TM-4424 Page 31
7-5. Inspecting And Cleaning Optional Spark Arrestor Muffler
Y Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
3
Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Y Stop engine and let cool.
1
Reinstall cleanout plug.
2
Tools Needed:
803 582 / Ref. 214 777-E
5/16 in
7-6. Servicing Engine Cooling System
Y Stop engine and let cool.
1
Radiator Draincock
2
Radiator Cap Cover
Change coolant according to engine
manual. Add coolant according to Section 4-6).
2
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if necessary.
After engine cools, check coolant level
again and add coolant if necessary.
1
803 581−D / Ref 214 777−F
TM-4424 Page 32
D302K 3+12
7-7. Adjusting Engine Speed
Y Stop engine and let cool.
Engine Speed
(No Load)
RPM (Hz)
Weld/Power
1880 (62.6)
Maximum
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine
speed with tachometer or frequency meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to
Stick − Weld Terminals Always On
position.
1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
. Do not set engine speed higher
than specified.
3
Engine Stop Lever
Use lever to stop engine if Start/
Preheat switch does not work.
3
Y Stop engine.
Close door.
2
Stop
1
Tools Needed:
803 581−D
D302K 3+12
TM-4424 Page 33
7-8. Servicing Fuel And Lubrication Systems
Y Stop engine and let cool.
Y After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.
1
2
3
Oil Filter
Oil Drain Valve And Hose
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 valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change information.
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and turn clockwise. Bleed air from fuel system according to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
6
To drain water from fuel system:
2
See engine manual.
To replace secondary fuel filter:
4
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter , reconnect fuel lines,
and reinstall clamps.
3
To drain sludge from fuel tank:
Y Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dispose of drained fuel in an environmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
5
Y Properly lift unit and secure
in a level position. Use adequate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
1
Tools Needed:
803 581 / Ref 214 777−E
TM-4424 Page 34
D302K 3+12
7-9. Overload Protection
Y Stop engine.
1
Fuse F1
F1 protects the stator exciter winding
from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F1 continues to open, check voltage regulator board PC3.
. If PC3 senses an overload con-
dition (shorted rotor), it protects
itself by stopping weld output.
Check rotor and brushes before
replacing PC3.
2
1
3
4
5
6
3
Circuit Breaker CB1 (Not
Shown)
Circuit Breaker CB2
4
Circuit Breaker CB3
5
Circuit Breaker CB7
6
Circuit Breaker CB8
CB1 protects the engine battery circuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected. If CB1
continues to open, check fuel solenoid FS1, the fuel pump, throttle solenoid TS1, integrated rectifier SR1,
engine alternator, glow plug, and circuit boards PC2 and PC3.
CB2 protects the engine wiring harness. If CB2 opens, the engine will
not crank. Press button to reset
breaker. If CB2 continues to open,
check fuel solenoid FS1, the fuel
pump, throttle solenoid TS1, integrated rectifier SR1, and circuit
boards PC2 and PC3.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops. If
CB3 continues to open, check circuit
boards PC1, PC2, and PC3.
CB7 protects the 115 volt ac output
to remote receptacle RC14. If CB7
opens, 115 volt output to RC14
stops. If CB7 continues to open,
check remote controls connected to
Remote receptacle RC14, and circuit board PC6.
CB8 protects the 24 volt ac output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
If CB8 continues to open, check remote controls connected to Remote
receptacle RC14, and circuit board
PC6.
803 566 / 803 580 / Ref 214 777−E
D302K 3+12
TM-4424 Page 35
7-10. Voltmeter/Ammeter Help Displays
Use the Voltmeter/Ammeter help
displays to diagnose and correct
fault conditions.
1
HL.P
20
. When a help code is displayed
normally weld output has
stopped but generator power
output may be okay.
. To
2
HL.P
21
1
22
Indicates a failure of meter display
module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, check PC1,
PC2, and the wiring between PC1
and PC2.
3
HL.P
reset help displays, stop
unit and then restart. See item
6 below to reset Help 25 display.
4
2
HL.P
23
HL.P
24
HL.P
25
6
Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
If this display is shown, check TH1.,
and the wiring between TH1 and
PC1.
3
5
Help 20 Display
Help 22 Display
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep engine access door closed when running to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting.
4
Help 23 Display
Indicates one of the rectifier output
SCR’s has failed. If this display is
shown, check the rectifier SCR’s.
5
Help 24 Display
Indicates weld open circuit voltage
(OCV) is too high (above 41 volts
dc). If this display is shown, check
main control module PC1.
6
Help 25 Display
Indicates a remote device connected to Remote Receptacle
RC13 or RC14 may be faulty. Help
25 is also displayed whenever a remote device has been connected to
RC13 or RC14 and then disconnected. Clear fault by stopping and
restarting the unit or by turning Process/Contactor switch to another
position. If problem continues,
check the remote device, filter
board PC6, and main control module PC1.
803 580 / 214 777-E
TM-4424 Page 36
D302K 3+12
Notes
D302K 3+12
TM-4424 Page 37
SECTION 8 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving fields.
5
Voltage
Regulator
Board PC3
2 Revolving Fields (Rotor)
Turn at 1885 rpm maximum for weld and
power. The speed and excitation current
of the field coils determine voltages in
stator windings.
4
3 Stator Windings
Supply power to exciter, generator power, and weld circuits.
Fuse F1
Current
Feedback
5 Voltage Regulator Board PC3
Changes ac output of stator windings to
dc to supply excitation current to the exciter revolving field.
Controls field current in response to
changes in output load.
If PC3 senses an overload condition
(shorted rotor), it protects itself by stopping excitation current (weld and generator power output stops).
6
Circuit Breakers CB4, CB5, and
CB6
Protect AC receptacles from overload.
7
AC Receptacles GFCI1, GFCI2
and RC11
Provide connection points and power for
auxiliary equipment.
8 Circuit Breakers CB7 and CB8
Provide overload protection for 24 and
115 volts ac portion of Remote 14 receptacle RC14.
1
3
2
Engine
6
Circuit
Breakers
CB4, CB5, CB6
7
AC
Receptacles
GFCI1, GFCI2,
RC11
11 Process/Contactor Switch R1
Selects weld process and weld output
on/off control.
TM-4424 Page 38
8
9
115 VAC
Filter Board PC6/Remote Receptacles RC13 and RC14
PC6 protects unit from high frequency.
RC13 connects remote amperage/voltage control to unit. RC14 connects
remote amperage/voltage and contactor controls to unit.
10 Voltage/Amperage Control R2
Adjusts weld output amperage or voltage level.
Stator Windings
Generator Power
9
When a remote control is connected to
a Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperage control to the remote
control.
3φ
Exciter
Revolving
Fields
(Rotor)
Weld
4 Fuse F1
Protects exciter windings from overload.
Circuit
Breaker
CB7
8
24 VAC
Filter Board
PC6/Remote
Receptacles
RC13, RC14
Circuit
Breaker
CB8
12
+10 VDC Output
Command Voltage
Control
Board
PC1
D302K 3+12
12 Control Board PC1
Controls weld output by changing
main rectifier SCR gate pulses
(conduction times) after comparing
amperage (CC) or voltage (CV)
feedback to selected voltage/amperage signal.
AC Or DC Control Circuits
Weld Current Circuit
External Circuits
3φ Power
13 Thermostat TH1
Thermostat opens and stops all
weld output if unit overheats.
14 Meter Board PC2
Displays preset and actual (rectified
and filtered) values of the weld voltage and amperage.
15 Main Rectifier
Changes ac weld current to dc.
18
CC
20
Stabilizer
Z1
CV
Works with PC1 (item 12) to controls weld output by changing rectifier SCR gate pulses (conduction
times) after comparing voltage (CV)
or amperage (CC) feedback to selected voltage or amperage signal.
16
CC Weld
Output
Terminal
16 Burden Resistor R3
Provides a path for a minimum SCR
holding current to flow.
Electrode
17 Hall Device HD1
Provides current feedback signal to
PC1.
Burden
Resistor R3
15
20
19
CV Weld
Output
Terminal
Capacitor
Bank C10
Main
Rectifier
18 Stabilizer Z1
Smooths (filters)
current.
weld
output
19 Capacitor Bank C10
Filters the dc output voltage of main
rectifier.
20 Work (−), CC, And CV Weld
Output Terminals
Provide weld output and allow
changing of output polarity.
20
17
Hall Device
HD1
SCR
Gating
Signals
10
CC or CV
Voltage
Feedback
11
Voltage/
Amperage
Control R2
D302K 3+12
Work
14
13
Process/
Contactor
Switch R1
Current
Feedback
Work (−) Weld
Output
Terminal
Thermostat
TH1
Meter
Board PC2
TM-4424 Page 39
SECTION 9 − EXPLANATION OF ELECTRICAL PARTS
elect_parts 7/04
9-1. Safety Precautions − Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.
D
D
D
D
Disconnect input power or stop engine before servicing.
Do not touch live electrical parts.
Do not operate machines with covers removed.
Have only qualified persons install, use, or service equipment.
PART NAME
FUNCTION
BATTERY
A source of DC voltage. Typically used in
Engine Driven equipment.
BRUSHES/SLIP
RINGS
Components that allow electrical connections
between stationary and rotating contacts.
PICTURE
CIRCUIT SYMBOL
+
SLIP
RINGS
BRUSHES
CAPACITOR
CHASSIS
A device that stores electrical energy. Large
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk”
capacitors can be used for HF protection.
TM-4424 Page 40
NON-POL.
C1
C1
The green ground wire of a primary cord is
connected to the machine frame (chassis) for
safety. Also, you may find many “HF bypass”
capacitors connected to chassis to reduce
High Frequency interference. Expect to see
this symbol used numerous times in circuit
diagrams. The picture shown here is from an
Engine Drive where several wires including
the battery are connected to the chassis.
CIRCUIT BREAKER A protection device that breaks a circuit when
current levels exceed its rating. Unlike a fuse
that needs to be replaced when blown, a
circuit breaker can be reset.
CIRCUIT COMMON
POLARIZED
+
CB1
When many wires are connected together,
rather than showing all the “lines” and “dots”,
this symbol may appear on the circuit. Look
for other Circuit Common symbols on a
circuit diagram. For instance, say 10 symbols
are found on a circuit, this means all ten
points are electrically tied together.
D302K 3+12
PART NAME
FUNCTION
CLAMP
A spring-loaded connection device. A good
example would be the “work clamp” used to
connect the weld cable from a power source
to the workpiece that will be welded.
CONTACTOR
A heavy duty relay. Usually used to make
and break the welding arc or primary power.
PICTURE
CIRCUIT SYMBOL
COIL
W
W
NRM OPEN
POINTS
CURRENT
TRANSFORMER
DASHED LINE
A transformer that produces an AC voltage
used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current.
A dashed line between parts means there is
a mechanical connection between these
parts. When a dashed line boxes in parts,
this means the parts make up an option or
are combined into one part. In all cases,
dashed lines do not conduct electricity. The
picture shown is a combination fan motor and
transformer in one part.
DIODE
A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
FAN MOTOR
This device provides cooling of the internal
parts of a welding power source.
CT1
OR
CT1
FM
D1
FM
FUSE
A protection device, usually an enclosed
piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
GAS OR WATER
SOLENOID
(VALVE)
These are electromechanical devices used to
start or stop the flow of shielding gas or
water.
HALL DEVICE
Produces a small DC voltage proportional to
the current it is sensing (usually welding
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
D302K 3+12
F1
GS1
OR
WS1
HD1
TM-4424 Page 41
PART NAME
IGBT
INTEGRATED
BRIDGE
RECTIFIER
FUNCTION
PICTURE
A device that is used as an “electronic
switch”. When a signal is applied to the gate
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically
used in “Inverter” designed welding machines
to control the welding output.
An arrangement of four diodes used to
change AC to DC.
C1
G1 (B1)
E1
+
AC
−
INTEGRATED
CIRCUIT
JUMPER LINK
CIRCUIT SYMBOL
+
AC
AC
AC
_
IC’s often called “chips” provide a complete
circuit function with inputs and outputs. A
good example would be the “Pulse Width
Modulation” chip used in many wire feeder
designs.
U1
Usually, the jumper link is a piece of brass
that connects two terminals together. Dashed
lines indicate possible locations for other
jumper links.
LIGHT EMITTING
DIODE
This device usually referred to by its initials
LED is used to tell you when a particular
circuit is activated. This function is very
helpful for troubleshooting.
MAGNETIC
AMPLIFIER
This device usually referred to as a
“Mag-Amp” is made up of coil windings and
an iron core similar to a transformer. It
controls a large welding current by varying a
small “control current”.
TE1
D1
MA1
METER
A measuring device. A “voltmeter” is a good
example.
V = voltmeter
A = ammeter
V
HM = hour
meter
MOSFET
TM-4424 Page 42
A device that is used as an “electronic
switch”. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
to control a relay, the speed of a motor, or
even the output of a welding machine.
D
G
AS
S
D302K 3+12
PART NAME
MOTOR
OPERATIONAL
AMPLIFIER
FUNCTION
M1
= DC
M1
= AC
Usually referred to as an “Op-Amp”, this IC
chip is very versatile and widely used on PC
boards. A typical use might be as a
“comparator”, comparing the command
signal to the feedback signal allowing the
welding output to be kept constant.
A device that uses “light” to get electrical
separation (isolation). This eliminates noise
that might be in one circuit from affecting
another circuit.
PILOT LIGHT
A light located on the front panel which
indicates if the machine is on or off.
PLUG
CIRCUIT SYMBOL
A device that converts electrical energy into
mechanical energy. Typically used to feed
wire in a MIG welding system, or pump
coolant in a recirculating liquid-cooling
system.
OPTICAL
COUPLER
POTENTIOMETER
OR
RHEOSTAT
PICTURE
Both devices have a moveable brush that
makes contact along a resistor, allowing you
to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
+
_
A1
OC1
1
PL
R1
CW = CLOCKWISE
CCW =COUNTERCLOCKWISE
A connection device that hangs loose with
wires coming out the back of it. Please note
that the plug terminals can be either male or
female.
MALE
FEMALE
PLG =
LOOSE
PLG1
RECEPTACLE
A connection device that is mounted or fixed.
Just like a plug, the terminals can be either
male or female.
MALE
FEMALE
RC =
MOUNTED
RC1
RELAY−−COIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
RESISTOR
RIBBON CABLE
This is an electromechanical device whose
contacts change state (the normally open
points close and the normally closed points
open) when proper voltage is applied to the
coil. These contact points in turn may control
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show
the contact points in the power off state.
A device which resists the flow of electric
current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
A connection device where the wires are laid
out flat. Usually to connect circuits from one
PC board to another PC board.
COIL
CR1
CR1
CR1
NRM OPEN NRM CLOSED
POINTS
POINTS
FIXED
R1
FIXED TAPPED
R1
26-CONDUCTOR
CABLE
RC54
D302K 3+12
RC44
TM-4424 Page 43
PART NAME
SCR
SHUNT
SNUBBER
SPARK GAP
STABILIZER/
REACTOR
SWITCH
FUNCTION
PICTURE
CIRCUIT SYMBOL
A Silicon Controlled Rectifier (SCR) is an
electrical device with three connections,
anode, cathode, and gate. It will allow current
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to
control the output to a load such as a welding
arc.
K
G
A
A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
SHUNT
A device used to absorb voltage spikes,
sometimes found connected across the
points of a relay.
SN1
The arrangement of two electrodes between
which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding.
G
When placed in a DC circuit, the inductor or
stabilizer as it is usually called, will oppose
any change in existing current. It is therefore
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
Z1
L1
A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
SPST
A multi-pole switch will use dashed lines to
connect poles.
SPDT
DPST
DPDT
SPST = Single Pole Single Throw
SPDT = Single Pole Double Throw
DPST = Double Pole Single Throw
DPDT = Double Pole Double Throw
MOMENTARY
SWITCH
A switch that “springs back” to its original
position.
LIMIT SWITCH
A switch mounted in the path of a moving
object and actuated by its passage.
PUSH BUTTON
SWITCH
A switch in which a button must be
depressed each time the contacts are to be
opened or closed.
ROTARY SWITCH
A switch in which its shaft must be rotated to
actuate the contacts.
S1
NRM OPEN
S1
NRM
CLOSED
S1
NRM
OPEN
PB1
NRM
CLOSED
PB1
S1
TM-4424 Page 44
S1
D302K 3+12
PART NAME
PRESSURE
SWITCH
TEMPERATURE
SWITCH
WATER FLOW
SWITCH
TERMINAL
ASSEMBLY
FUNCTION
A change in the pressure of a gas or liquid
will actuate this switch.
Typically used to protect engines, this switch
is actuated by heat.
A switch that is actuated by the flow of a
liquid. Typically used to protect
“water-cooled” torches.
A connection point for primary power and the
jumper links that are used to match the input
voltage to the machine. Usually, the terminal
assembly is marked with the letters “TE”, but
the electrical symbol looks identical to a
standard terminal strip.
PICTURE
CIRCUIT SYMBOL
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
TE1
TE1
TERMINAL STRIP
THERMISTOR
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
TRANSISTOR
An insulated connection point for wires. They
are used for the ease of making multiple
connections and can be a convenient point
for making electrical checks when
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
1T
42 42 104 105 74
B
Most commonly used as an electronic switch.
There are two basic types, PNP and NPN.
This refers to their internal design, which
determines current flow direction.
D
E
105
A thermally sensitive resistor. There are two
types of thermistor, PTC (Positive
Temperature Coefficient) and NTC (Negative
Temperature Coefficient). A PTC thermistor’s
resistance will increase as the temperature
goes up, where as an NTC thermistor’s
resistance will decrease as the temperature
goes up. Primarily used for “Fan on Demand”
and “Thermal Shutdown” circuits.
This is a switch that closes its normally open
contacts (or opens its normally closed
contacts) when a preset temperature is
reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when
needed and shutting off the output of a
welding power source if it is overheating.
C
104
RT1
OR
TH1
TP1
TP1
NRM OPEN NRM CLOSED
Q1
C
B
NPN
D302K 3+12
A
Q1
C
B
E
PNP
E
TM-4424 Page 45
PART NAME
TRANSFORMER
TRIAC
TWISTED WIRE
VARISTOR
WIRES WITH
CONNECTION
TM-4424 Page 46
FUNCTION
A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
PICTURE
CIRCUIT SYMBOL
T1
IRON
CORE
T1
FERRITE
CORE
T1
AIR
CORE
An electronic AC switch. It is turned on by a
gate signal similar to an SCR.
Wires are twisted to prevent “electrical noise”
from interfering with the circuit. A good
example is the red and white gate leads
going to an SCR. Typically, these wires are
twisted together to help prevent the SCR
from misfiring.
A protection device whose resistance is
dependent on the voltage applied to it. In
normal operation it has a high resistance;
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
Q1
RED
WHT
VR1
When lines (wires) cross on a circuit diagram
and there is a “black dot”, this means that the
two wires are electrically connected together.
The method of connection (bolted, friction
lugs, etc.) is not indicated with this symbol.
However, a “white dot” indicates that the
method of connection is a terminal strip. Of
course, no dot means no connection.
D302K 3+12
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12
TM-4424 Page 47
SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
. See Section 10-2 for test points and
values and Section 14 and following
for parts location.
. Use MILLER Testing Booklet (Part
No. 150 853) when servicing this
unit.
Note
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see
Section 7-10).
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch R1 in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/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 RC13
or 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 proper
connections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 7-10).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
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 board
PC3. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check
rotor and brushes before replacing PC3.)
Check Voltmeter/Ammeter help displays (see Section 7-10).
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 necessary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
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 rotor
and 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 if
necessary.
High weld output.
Repair or replace remote control device.
Check hall device HD1, and replace if necessary (see Section 10-2).
TM-4424 Page 48
D302K 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.
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if necessary.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Check main control board PC1 and connections, and replace PC1 if necessary.
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 rotor
and brushes before replacing PC3.)
Check SCR’s in main rectifier, and replace if necessary. If any SCR’s are replaced, check capacitors
C1 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 4-9
or 4-10).
No 24 volt or 115 volt ac output at Re- Reset circuit breaker CB7 (24 volt) or CB8 (115 volt) (see Section 7-9).
mote receptacle RC14.
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle circuit breakers (see Section 6-1).
tacles; weld output okay.
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 board
PC3 (see Section 10-9). (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping
weld output. Check rotor and brushes before replacing PC3.)
Reset circuit breaker CB3 (see Section 7-9).
Check Voltmeter/Ammeter help displays (see Section 7-10).
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 necessary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
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 rotor
and brushes before replacing PC3.)
High output at generator power ac
receptacles.
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 rotor
and brushes before replacing PC3.)
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 board
PC3 (see Section 10-9). (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping
weld output. Check rotor and brushes before replacing PC3.)
D302K 3+12
TM-4424 Page 49
C. Engine
Trouble
Engine will not crank.
Remedy
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.
Reset circuit breaker CB2 (see Section 7-9).
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 condition
of contacts. Replace CR1 if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM 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 for
fuel 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 coolant
temperature 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 condition
of 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. Replace
FS1 if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 7-4 and 7-8).
See engine manual.
TM-4424 Page 50
D302K 3+12
Trouble
Battery discharges between uses.
Remedy
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; Dry engine according to run-in procedure (see Section 13).
wetstacking occurs.
Notes
D302K 3+12
TM-4424 Page 51
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
V7,R7
V6,
R6
R13
V8,R8
E
V9,R9
V1,R1
V2,R2
I1
V3,R3
V4,R4
See Section 10-9
for PC3 data
V5,R5
See Section
10-11 for PC2
data
V23
Engine
control
relay CR1
V25
V24
V26
R11
V10,
R10
V11,
R12
V12,
R13
TM-4424 Page 52
D302K 3+12
V18, B,D
V17,
A,C
E
E
E
E
E
E
E
E
V21
V22
V19
V20
V13
V14
V15 V16
See Section 10-4
for waveforms
A,B,C,D,E
See Section
10-5 for
PC6 data
See Section
4-10 for RC14
information
218 546-C
D302K 3+12
TM-4424 Page 53
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)
Test Equipment Needed:
Voltage Readings
a)
Tolerance − ±10% unless specified
b)
Condition − 70°F (21°C); cold machine
(no warm-up); no load; weld/power rpm
unless noted
Reference − single arrow: reference to
circuit common (lead 42); double
arrow: reference to points indicated
Process/Contactor switch R1 in Weld
Terminals Always On − Stick (Dig-B)
position unless noted
Wiring Connections − see Section 12
c)
d)
e)
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
Resistance Values
Tolerance
specified
b)
Condition − 70°F (21°C); cold
machine (no warm-up)
c)
Wiring Connections
Section 12
d)
Stop engine before checking
resistance
R1 thru R8
R9
R10
R11
−
±10%
a)
unless
−
see
Less than 1 ohm
22 ohms
14.2 ohms
Empty fuel tank: 250 ohms
Full tank: 0 ohms
1 ohm
15.5 ohms
V9
+ 61 volts dc
V10
+12 volts dc
V11
+12 volts dc while cranking engine
V12
+12 volts dc while cranking and running
engine
V13
0 to +5 volts dc from Weld Terminals
Always On−Wire position to Remote−Wire
position of Process Contactor switch R1 (in
0.45 volt increments)
V14
+5 volts dc
a)
Tolerance − ±5% unless specified
V15
0 to +5 volts dc from min to max of
Voltage/Amperage control R2
b)
V16
+5 volts dc
Condition − 70°F (21°C); cold
machine (no warm-up); no load;
weld/power rpm unless noted
V17
+41 volts dc with Process/Contactor switch
R1 in Weld Terminals Always On − Stick
position; +20 volts dc with R1 in TIG
position
c)
Process/Contactor switch R1 in
Weld Terminals Always On − Stick
(Dig-B) position unless noted
V18
14 to +40 volts dc with Process/Contactor
switch R1 in Weld Terminals Always
On−Wire position
I1
3.1 amps dc
4.6 amps at 20 volt, 200 amp load
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 switch
S1 in Start position
V25
+12 volts dc input with Start/Preheat switch
S1 in Start or Run position
V26
Ground path for CR1:
Normal operation: 0 volts dc
Fault shutdown: +12 volts dc
TM-4424 Page 54
R12
R13
Amperage Readings
D302K 3+12
10-4. Waveforms For Sections 10-2
. The waveforms represent the output of the welding power source. When operating properly, the power source waveforms match those shown.
2 ms 50 V
2 ms 20 V
gnd
gnd
A. CC/DC Open-Circuit Voltage, Process/Contactor Switch R1 In Weld Terminals Always On
− Stick (Dig B) Position, Voltage/Amperage
Control R2 At Max
B. CV/DC Open-Circuit Voltage, Process/Contactor Switch R1 In Weld Terminals Always
On − Wire Position, Voltage/Amperage Control R2 At Max
2 ms 50 V
gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Process/Contactor Switch R1 In Weld Terminals
Always On − Stick (Dig B) Position, (Resistive
Load)
5 ms 2 V
2 ms 20 V
gnd
D. CV/DC Output, 30 Volts DC, 250 Amperes, Process/Contactor Switch R1 In Weld Terminals
Always On − Wire Position, (Resistive Load)
gnd
Test Equipment Needed:
E. SCR Gate Pulses w/Respect To Cathode At No
Load, Process/Contactor Switch R1 In Weld
Terminals Always On − Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max
D302K 3+12
TM-4424 Page 55
10-5. Filter Board PC6 Testing Information
Y Stop engine.
See Section 10-6 for specific values during testing. Voltage readings tolerance ±10%.
1
2
Filter Board PC6
Receptacle RC2
1
2
Test Equipment Needed:
803 816 / 217 008
TM-4424 Page 56
D302K 3+12
10-6. Filter Board PC6 Test Point Values
a) Tolerance
specified
−
±10% unless
b) Reference − to circuit common
(lead 42) unless noted
PC6 Voltage Readings
c) Condition − no load; weld/power rpm unless noted
d) Process/Contactor switch S6
in Weld Terminals Always On −
Stick position
Receptacle
Pin
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 between
pins A and B
8
Command common
9
Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperage
control
10
Current feedback: 1 volt dc per 100 arc amperes
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/amperage
control R2 at max
3
Circuit common
RC3
D302K 3+12
Value
TM-4424 Page 57
10-7. Main Control Board PC1 Testing Information
Y Stop engine.
See Section 10-8 for specific values during testing. Voltage readings tolerance ±10%.
1
2
3
4
1
Main Control Board PC1
Plug PLG6
Plug PLG7
Plug PLG11
4
2
3
Test Equipment Needed:
803 816
TM-4424 Page 58
D302K 3+12
10-8. Main Control Board PC1 Test Point Values
a) Tolerance
specified
−
±10% unless
b) Reference − to circuit common
(lead 42) unless noted
PC1 Voltage Readings
c) Condition − no load; weld/power rpm unless noted
d) Process/Contactor switch R1
in Weld Terminals Always On −
Stick position
Receptacle
Pin
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/amperage
control
H3
Circuit common
J1
Not used on this model
J3
+10 volts dc output
K1
+5 volts dc output
K3
24 volts ac input
A1
0 to +5 volts dc from Weld Terminals Always On−Wire position to Remote−Wire position of Process
Contactor 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 between pins A and B
C1
+5 volts dc output
C2
Circuit common
C3
SCR fault signal; +5 volts dc output if any SCR fails
PLG7
D302K 3+12
Value
TM-4424 Page 59
Receptacle
PLG11
TM-4424 Page 60
Pin
Value
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
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
D302K 3+12
10-9. Voltage Regulator Board PC3 Testing Information
Y Stop engine.
See Section 10-10 for specific values during testing. Voltage readings tolerance ±10%.
1
2
3
Voltage Regulator Board PC3
Receptacle RC1
Receptacle RC2
1
2
3
Test Equipment Needed:
803 816
D302K 3+12
TM-4424 Page 61
10-10. Voltage Regulator Board PC3 Test Point Values
a) Tolerance
specified
−
±10% unless
b) Reference − to circuit common
(lead 42) unless noted
PC3 Voltage Readings
c) Condition − no load; weld/power rpm unless noted
d) Process/Contactor switch R1
in Weld Terminals Always On −
Stick position
Receptacle
Pin
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
1
120 volts ac input with respect to pin RC1-3
2
120 volts ac input with respect to pin RC1-3
3
Not used
4
Not used
5
158 volts ac input with respect to pin RC2-8
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
RC2
TM-4424 Page 62
Value
D302K 3+12
10-11. Meter Display Board PC2 Testing Information
Test Equipment Needed:
Y Stop engine.
See Section 10-12 for specific values during testing. Voltage readings tolerance ±10%.
1
Meter Display Board PC2
1
803 816 / 214 536
10-12. Meter Display Board PC2 Test Point Values
a) Tolerance
specified
−
±10% unless
b) Reference − to circuit common
(lead 42) unless noted
PC2 Voltage Readings
c) Condition − no load; weld/power rpm unless noted
d) Process/Contactor switch R1
in Weld Terminals Always On −
Stick position
Receptacle
Pin
RC1
1
+12 volts dc input with respect to pin RC1-2
2
Circuit common
3
Serial data line
4
Serial data line
D302K 3+12
Value
TM-4424 Page 63
10-13. Replacing Brushes And Cleaning Slip Rings
Y Stop engine and let cool.
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 caps
and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6
Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Y Stop engine.
Install brushes, caps, bar, bracket,
and brush leads. Tighten bracket
hardware.
6
1
2
3
4
5
5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)
New Length
Tools Needed:
Replace
Damaged Brushes
Ref. 803 817 / Ref. 803 686
TM-4424 Page 64
D302K 3+12
10-14. Checking Unit Output After Servicing
. Also use output waveforms to
check unit output after servicing (see Section 10-4).
Check engine speeds, and adjust if
necessary (see Section 7-7).
Place Process/Contactor switch
R1 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/power
speed (1880 rpm).
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts ac present at
GFCI1 and GFCI2, and 252 to 260
volts ac at RC11.
If correct voltage is not present, repeat troubleshooting procedures in
Section 10-1.
3
Check open-circuit voltage across
weld output terminals according to
Section 10-2. If correct voltages are
not present, repeat troubleshooting
procedures in Section 10-1.
1
Y Stop engine.
Allow engine to cool, and then complete pre-operational checks in
table.
2
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-7).
Test Equipment Needed:
Tools Needed:
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
D302K 3+12
803 816
TM-4424 Page 65
SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
Y Stop engine and let cool. Disconnect battery negative (−)
cable.
Use Section 10-1 to determine if trouble
is in stator, rotor, engine or combination
of these components.
1
Engine Manifold Screw
2
Generator Mounting Screws
3
Engine Mounting Screw
4
Engine Lifting Eyes
Remove side panels, covers, and
doors. Retain all hardware.
Drain radiator according to Section 7-6
and engine manual. Disconnect hoses
at radiator.
Remove rear upright, right fan guard,
and radiator assembly.
Disconnect flexible exhaust pipe at engine manifold.
Disconnect fuel line at engine.
. To aid in reassembly, mark leads
before disconnecting. See lead list
summary in Section 12 for connection information.
Disconnect:
1
F
generator cables from rectifier assembly
F
generator power leads from terminal strip TE1
F
engine wiring harness at in-line
connector
F
engine ground strap from base.
Use a hoist to evenly lift and remove
engine/generator assembly.
Go to Section 11-2.
3
2
4
Remove brushes
before removing
endbell or rotor.
803 818
TM-4424 Page 66
D300K 3+12
11-2. Disassembly Of Generator
D
4
A
5
2
3
B
14
C
1
Torques:
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)
803 686
Y Do not damage stator or rotor windings during this procedure.
Y Use hoist and lifting strap to carefully
remove generator components.
1
Brushes
2
Stator
3
Endbell
4
Rotor
5
Stud
Remove brushes from brushholder assembly
before disassembling generator.
D300K 3+12
Remove engine and rotor by removing nuts
from studs and separating stator from engine
adapter. With engine properly supported, remove hardware securing endbell to stator.
Reassembly Instructions:
Reinstall engine and generator parts as
needed using torque values in table.
Reinstall brushes in brushholder assembly.
Reinstall engine/generator assembly in unit.
Reinstall mounting hardware and torque to 50
ft lb (68 N.m).
Reconnect fuel line and exhaust pipe. Torque
engine manifold screws to 30 ft lb (41 N.m).
Reinstall radiator and rear upright. Refill radiator with coolant (see Section 7-6 and engine manual).
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative (−) battery cable. Reinstall cover, panels, and doors.
TM-4424 Page 67
11-3. Replacing Rectifier SCR Modules
Y Stop engine and let cool. Disconnect battery negative (−)
cable.
. Be sure to follow torque specifica-
tions in table when installing and
connecting SCR module. Retorque
mounting hardware after four
hours.
SCR Module Torques:
SCR Mounting Screw
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m)
After four hours re-torque to
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m)
SCR Connection Screw Terminal
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m)
1
Rectifier Assembly
2
SCR Module
3
SCR Connection Screw
4
SCR Mounting Screw
Remove left side panel. Remove rectifier assembly screws and slowly tilt assembly out.
Remove defective SCR module.
Clean mounting surface where module
will be installed
Apply a thin layer of supplied heat sink
compound to mounting surface of
module.
Install new SCR module. Follow torque
specifications in table when installing
part. Remember to re-torque hardware as specified.
Remove protective foam from SCR terminals (if applicable) before connecting
leads.
1
2
3
4
803 703
TM-4424 Page 68
D300K 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 inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model
Circuit
Diagram
Serial Or Style Number
D302K 3+10 CC/CV Models
LE185330 and following
218 546-C
Circuit Board PC6
(HF Filter Board)
LE185330 and following
217 005-A
Circuit Board PC2
(Meter Display)
LE185330 and following
214 535-A
Wiring
Diagram
See Table 12-1
Notes
Start Your Professional
Welding Career Now!
D302K 3+12
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
TM-4424 Page 69
Figure 12-1. Circuit Diagram For D300K 3+12 Effective With Serial No. LE185330 And Following
TM-4424 Page 70
D302K 3+12
218 546-C
D302K 3+12
TM-4424 Page 71
217 005-A
Figure 12-2. Circuit Board PC6 (HF Filter) Effective With Serial No. LE185330 And Following
TM-4424 Page 72
D302K 3+12
214 535-A
Figure 12-3. Circuit Board PC2 (Meter Display) Effective With Serial No. LE185330 And Following
D302K 3+12
TM-4424 Page 73
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-applied
grease had been present.
Lead
Connections
Lead
Connections
−−−−
−−−−
−−−−
−−−−
11A
16A
16A
16B
17A
18A
19A
19A
19B
21A
30A
30A
30B
30B
31A
40A
40B
41A
42A
42A
42A
42AA
PLG1 TO G1
PLG1 TO G2
PLG1 TO K1
PLG1 TO K2
STATOR TO RECT.
PLG6 (A3) TO R−3 RIGHT
SCR’S CV (+) TO C10 (+)
SCR CV (+) TO R3 (RIGHT)
Z1 TO SCR’S CC (+)
Z1 (CV) TO CV OUTPUT STUD
PLG6 (C3) TO R−3 LEFT
Z1 (CC) TO CC OUTPUT STUD
Z1 TO R3 (LEFT)
STATOR TO RECT.
PLG6 (B3) TO R−3 CENTER
SCR’S (−) TO C10 (−)
C10 (−) TO NEG OUTPUT STUD
HEAT SINK (−) TO R3 (CENTER)
STATOR TO RECT.
CR1 (8) TO PLG5 (1)
CR1 (8) TO PLG9 (1)
STARTER TO CB1 (BATTERY)
GROUND STUD TO TE1
GROUND TERMINAL TO PLG9 (3)
S2 TO GROUND TERMINAL
GFCI−1 (GRND) TO GROUND STUD ON POWER
PANEL
GFCI−2 (GRND) TO GROUND STUD ON POWER
PANEL
GROUND TERMINAL TO PLG5 (2)
SR2 TO GROUND TERMINAL
TE1 TO BASE GROUND
FUEL PUMP TO GROUND TERMINAL
GR STUD POWER PANEL TO RC11 (GR)
PC6 TO FRT PANEL GROUND
PLG6 (J1) TO EXIT
FUEL SENDER GROUND TO GROUND TERMINAL
FUEL SENDER GROUND TO PLG1 (8)
ENGINE BLOCK GROUND TO GROUND TERMINAL
GROUND TERMINAL TO GROUND TERMINAL
T1−5 TO TE−1
FRONT PANEL GROUND STUD TO TE1
AMP METER (+) TO ALT (B)
CB2 TO CB3
CB2 TO ALT (B)
S1 (30) TO AMMETER (+)
CB1 (AUX) TO AMP METER (−)
CB3 TO CR1 (6)
STARTER TO FS1
STARTER TO S1 (50)
S1 (50) TO PLG1 (6)
CB2 TO CR1 (2)
CR1 (4) TO SR1
SR1 TO S4 (WIPER)
S4 (NO) TO CR1 (O)
CR1 (O) TO BARE
SR2 TO FS1
S4 (NC) TO PLG1 (4)
SR2 TO FUEL PUMP
ALT (IG) TO BARE
SR2 TO BARE
SR2 TO BARE
CR1 (1) TO PLG1 (7)
S1 (17) TO S1 (19)
S1 (17) TO GLOW PLUG
S1 (19) TO SR1
PLG1 (2) TO S2
PLG1 (3) TO S3
70A
71A
80
80A
81A
81A
84A
84C
85A
87A
90A
90A
90C
90D
91A
91A
91B
91B
91C
92A
92A
92B
92B
94A
94B
95A
95B
99C
100A
100B
101A
105A
106A
107A
108A
109A
112A
113A
114A
117A
120A
121A
130A
132A
135A
135C
136A
136C
137A
140A
141A
148A
148C
150A
160A
161A
162A
165A
166A
167A
180A
181A
182A
188A
189A
190A
191A
PLG7 (F2) TO PC5 (J)
PLG1 (5) TO FUEL LEVEL SENDER
PC6 − EXIT
STATOR TO TE1
PLG6 (K3) TO CB8
STATOR TO CB8
GFCI−1 (H) TO CB6
PLG10 (3) TO #84 STATOR LEAD
GFCI−2 (H) TO CB4
PC6 − CB7
STATOR TO TE1 (C)
TE1 (C) TO RC11 (WB)
GFCI−1 (N) TO TE1 (C)
GFCI−1 (N) TO GFCI−2 (N)
STATOR TO TE1 (B)
TE1 (B) TO CB5
PLG10 (1) TO #91 STATOR LEAD
STATOR TO VR
STATOR TO CB7
STATOR TO TE1 (A)
TE1 (A) TO CB5
PLG10 (2) TO #92 STATOR LEAD
STATOR TO VR
CB5 TO RC11 (X)
CB5 TO CB6
CB5 TO RC11 (Y)
CB5 TO CB4
PLG10 (4) TO #99 STATOR LEAD
STATOR TO SPLICE (PC3)
PLG10 (5) TO STATOR 100A
STATOR TO FUSE 1
PLG10 (6) TO BRUSH
PLG6 (F3) TO PLG9 (6)
PLG6 (D2) TO PLG9 (9)
PLG10 (7) TO BRUSH
PLG6 (E3) TO PLG9 (5)
PLG6 (E2) TO PLG9 (11)
PLG6 (H3) TO PLG9 (4)
PLG10 (8) TO F1
PLG6 (G3) TO PLG9 (8)
PLG7 (E1) TO PLG9 (2)
PLG7 (C3) TO PLG9 (10)
PLG6 (J3) TO PLG9 (7)
PC6 − CB8
PLG6 (G2) TO PC6 (6)
RC13 (C) TO RC3 (1)
PLG7 (F1) TO PC6 (8)
RC13 (A) TO RC3 (3)
PLG6 (H2) TO PC6 (9)
PLG7 (F3) TO PC6 (10)
PLG6 (F2) TO PC6 (4)
PLG6 (D3) TO PC6 (2)
RC13 (B) TO RC3 (2)
PLG7 (B3) TO PC6 (7)
PLG7 (B1) TO PLG3 (4)
PLG7 (A1) TO PLG3 (5)
PLG6 (K1) TO PLG3 (6)
PLG6 (C2) TO PLG2 (1)
PLG6 (B2) TO PLG2 (2)
PLG6 (A2) TO PLG2 (3)
PLG6 (F1) TO EXIT
PLG6 (G1) TO EXIT
PLG6 (H1) TO EXIT
PLG7 (C1) TO PLG4 (1)
PLG7 (D1) TO PLG4 (2)
PLG6 (A1) TO PLG5 (3)
PLG6 (C1) TO PLG5 (4)
42AB
42B
42B
42B
42C
42C
42C
42C
42D
42E
42F
42G
42TG
42Y
43A
43B
43C
43D
44A
45A
46A
47A
47B
48B
52A
52B
53A
53B
53C
53D
53E
53F
53G
53H
54A
55A
55B
55C
56A
57A
TM-4424 Page 74
D302K 3+12
SECTION 13 − RUN-IN PROCEDURE
run_in1 8/01
13-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1
2
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
.
Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
2
Engine Exhaust Pipe
1
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
D302K 3+12
TM-4424 Page 75
13-2. Run-In Procedure Using Load Bank
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
4
2
1
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place Voltage/Amperage control in
minimum position, and Process/
Contactor switch in Weld Terminals
Always On − Stick position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
3
Set load bank switches and then
adjust generator Voltage/Amperage control so load equals rated
voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
. Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place
Voltage/Amperage control in minimum position, then turn off load
bank to remove load. Run engine
several minutes at no load.
Y Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
TM-4424 Page 76
D302K 3+12
13-3. Run-In Procedure Using Resistance Grid
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
6
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place Voltage/Amperage control in
minimum position, and Process
Contactor switch in Weld Terminals
Always On − Stick position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
5
Start engine and run for several
minutes.
Set grid switches and then adjust
generator Voltage/Amperage control so load equals rated voltage
and current of the generator (see
nameplate, rating label, or the specifications section in this manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
. Check oil level frequently during run-in; add oil if needed.
After one hour (minimum), place
Voltage/Amperage control in minimum position, then shut down grid
to remove load. Run engine several
minutes at no load.
Y Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
D302K 3+12
TM-4424 Page 77
Notes
TM-4424 Page 78
D302K 3+12
TM-4424B
April 2005
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
Eff w/LE185330 And Following
For OM-4424 (215 179) Revisions A Thru E
SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING
. Hardware is common and not
available unless listed.
Wirng harnesses are listed at
the end of parts section.
8
9
10
11
13
12
6
7
4
14
15
5
22
17
101
23
16
102
21
20
19
3−Fig.14-5
2
92
93
100
18
90
91
86
87
1−Fig.14-3
98
83
99
82
97−Fig.14-2
84
89
81
80
85
79
88
78
94
95
96
Figure 14-1. Main Assembly
TM-4424 Page 80
D302K 3+12
Eff W/LE185330 And Following
29
28
26
25
30
27
39
38
33
24
67
37
32
31
34
66
40
65
64 63
68
69
59
76
77
62
60
58
57
56
55
54
70−Fig.14-4
75
74
30
36
35
42
47
61
43
45
48
41
49
43
46
44
50
51
53
71
52
53
73
72
803 748−C
D302K 3+12
TM-4424 Page 81
Eff W/LE185330 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly
. . . 1 . . . . . . . . . . Figure 14-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . Figure 14-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . +213547 . . Panel, Engine Side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . PC1 . . . . 214769 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 218469 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 212620 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . +213542 . . Cover, Top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 202629 . . Cover, Radiator Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 213633 . . Bracket, Cover Top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 212624 . . Shroud Adapter, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 212606 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . +213544 . . Upright, Rear SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 220295 . . Bracket,Stiffener (Eff w/LE304607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . . 176109 . . Label, Caution Using Ether To Aid Engine Etc . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . . 215269 . . Label, Diesel Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . . 190126 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . +213546 . . Door, Engine Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-4424 Page 82
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D302K 3+12
Eff W/LE185330 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . . 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
D302K 3+12
TM-4424 Page 83
Eff W/LE185330 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 89 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . .
. . . 90 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 91 . . . . . . . . . . . . . . 213484 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 92 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 93 . . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor /Rectifier Tray) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 94 . . . . . . . . . . . . . +213543 . . Upright, Front SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . . 200795 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 96 . . . . . . . . . . . . . . 213541 . . Panel, Front Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 97 . . . . . . . . . . Figure 14-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 98 . . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 99 . . . . . . . . . . . . . . 216347 . . Label, Rating Card Code (Provide Serial No. When Ordering) . . . . . . . . .
. . 100 . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . .
. . 101 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 102 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 215326 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4424 Page 84
D302K 3+12
Eff W/LE185330 And Following
. Hardware is common and not
available unless listed.
Wirng harnesses are listed at
the end of parts section.
13
12
10
11
14
9
15
8
16
17
7
6
18
5
19
4
3
20
40
39
2
27
26
25
28
21
29
24
38
1
37
22
23
31
33
36
30
32
34
35
803 749
Item
No.
Dia.
Mkgs.
Part
No.
Figure 14-2. Panel, Front w/Components
Description
Quantity
Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 97)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . . . . . . . . . . . 097926 . .
. . . . . . . . . . . . . . 072590 . .
. . . . . . . . . . . . . . 170391 . .
. . . . . . . . . . . . . . 190323 . .
. . . . . . . . . . . . . . 108864 . .
. . . . . . . . . . . . . . 097922 . .
........................
. . . . PC6 . . . . 217008 . .
. . CB7, CB8 . . 083432 . .
D302K 3+12
Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms Protective Cap Size 16−16s Metal . . . . . . . . . . . . . . . . . . . .
Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
2
TM-4424 Page 85
Eff W/LE185330 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-2. Panel, Front w/Components (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
. . . . RC3 . . . . 214899 . .
. . . . . . . . . . . . . . 218556 . .
. . . . . . . . . . . . . . 214543 . .
. . . . . . . . . . . . . . 134201 . .
. . . . PC2 . . . . 214660 . .
. . . . . R1 . . . . . 214760 . .
. . . . . R2 . . . . . 193118 . .
. . . . . S4 . . . . . 021467 . .
. . . . . S1 . . . . . 207720 . .
. . . . . . . . . . . . . . 039047 . .
. . . . . . . . . . . . . . 010381 . .
. C13, 14, 15 . 128750 . .
. . . . . . . . . . . . . . 209056 . .
. . . . RC11 . . . . 182954 . .
........................
. . . . . . . . . . . . . . 213509 . .
. . GFCI1, 2 . . 151981 . .
. . C11, C12 . . 217054 . .
. . CB4, CB6 . . 093996 . .
. . . . CB5 . . . . 203026 . .
. . . . GRD . . . . 083030 . .
. . . . . . . . . . . . . . 010915 . .
. . . . . . . . . . . . . . 601836 . .
........................
. . . . . . . . . . . . . . 181169 . .
. . . . . . . . . . . . . . 186621 . .
. . . . . . . . . . . . . . 180735 . .
. . . . . . . . . . . . . . 039046 . .
. . FUEL/HM . . 214768 . .
. . . . . . . . . . . . . . 021385 . .
. . . . . AM . . . . . 118060 . .
Receptacle, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . .
Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . .
Switch, Ignition 3 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . .
Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . .
Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . .
Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . .
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meter, Amp Dc 60−0−60 2.250 Dia High Profile Stainl . . . . . . . . . . . . . . . .
1
1
1
4
1
1
1
1
1
2
3
3
4
1
1
1
2
2
2
1
1
4
3
1
3
3
3
1
1
1
1
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4424 Page 86
D302K 3+12
Eff W/LE185330 And Following
. Hardware is common and not
4
available unless listed.
Wirng harnesses are listed at
the end of parts section.
3
2
5
6
1
7
8
9
803 798
Figure 14-3. Control Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Control Panel (Figure 14-1 Item 1)
...
...
...
...
...
...
...
...
...
...
1
2
3
4
4
5
6
7
8
9
..............
..............
. . . . CB1 . . . .
. . . . CR1 . . . .
. . . . CR1 . . . .
..............
. . . . . F1 . . . . .
. . . . CR3 . . . .
. . SR1, SR2 . .
. . CB2, CB3 . .
220981
129524
190374
199999
223669
046432
085874
197325
035704
083432
..
..
..
..
..
..
..
..
..
..
Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Dpst−no 30a 6pin Flange (Prior to LF065150) . . . . . .
Relay Assy (Eff w/LF065150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
1
2
1
1
1
1
1
1
2
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
D302K 3+12
TM-4424 Page 87
Eff W/LE185330 And Following
5
. Hardware is common and not
available unless listed.
4
Wirng harnesses are listed at
the end of parts section.
1
6
7
3
2
8
9
10
11
12
13
14
20
19
18
17
16
803 771
15
Figure 14-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-4. Generator (Figure 14-1 Item 70)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
. . . ROTOR . . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
. . STATOR . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
212474
053390
192600
159918
193515
602211
192686
602211
192686
212641
212470
160943
167788
218552
047879
161306
126984
005614
125548
158832
. . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . .
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
1
1
1
1
1
6
6
6
6
4
1
1
4
1
1
2
2
2
1
2
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4424 Page 88
D302K 3+12
Eff W/LE185330 And Following
. Hardware is common and not
6
available unless listed.
1
Wirng harnesses are listed at
the end of parts section.
3
2
7
10
8
5
4
9
803 685-A
Figure 14-5. Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-5. Rectifier Assembly (Figure 14-1 Item 3)
....................
... 1 ..............
. . . 2 . . MOD1,2,3 . .
. . . 3 . . MOD4,5,6 . .
... 4 ..............
... 5 ..............
... 6 ..............
. . . 7 . . . . TH1 . . . .
. . . 8 . . . . C1−6 . . . .
. . . 9 . . . C7,8,9 . . .
. . . 10 . . . . . . . . . . . . . .
....................
217081
211984
218296
218292
212602
212639
212601
213930
215611
048420
217085
181853
. . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . .
. . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
3
1
3
1
1
3
3
1
4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
D302K 3+12
TM-4424 Page 89
Eff W/LE185330 And Following
Note
Item
No.
Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
. . . . . . . . . . . . . . . . . . . . 217141
. . . . . . . . . . . S4 . . . . 199691
. . . . . . . . SR1, SR2 . 035704
. . . . . . . . . . CB1 . . . 190374
. . . . . . . . CB2, CB3 . 083432
. . . . . . . . . . PLG1 . . . 214932
. . . . . . . . . . . . . . . . . . . 214933
. . . . . . . . . . . . . . . . . . . 192168
. . . . . . . . . . . . . . . . . . . 214934
..
..
..
..
..
..
..
..
..
Harness, Engine Kubota (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Spdt 6a 125vac On−none−mc Spd Term . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . .
Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect 250 1pin 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
2
1
7
1
1
....................
. . . . . . . . . . PLG2 . . . .
. . . . . . . . . . PLG9 . . . .
....................
....................
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . PLG7 . . . .
. . . . . . . . . . PLG9 . . . .
. . . . . . . . . PLG10 . . .
....................
....................
. . . . . . . . . . PLG5 . . . .
....................
....................
....................
217002
150316
214951
214933
214934
147992
193184
193183
215261
215262
215265
215343
113750
217000
215340
214933
. . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
1
1
1
1
1
2
7
1
1
1
2
....................
. . . . . . . . . PLG11 . . .
....................
....................
214984
193183
207716
207718
. . Harness, Rectifier CC/CV (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
6
3
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB4, CB6 . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
TM-4424 Page 90
D302K 3+12
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Serial/Style Number
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
Zip
File a claim for loss or damage during
shipment.
1/04
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