engine driven Miller D302K3-12 Technical Manual

TM-4424B

April 2005 2005

Eff. w/Serial Number LE185330 And Following

Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Carbon Arc (CAC-A) (CAC-A) Cutting Cutting and Gouging

Description

Engine Driven Welding Generator

TABLE OF CONTENTS SECTION 1-1. 1-2. 1-3. 1-4.

1 − SA SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2

SECTION 2 − DE D EFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − SP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 7 8 9

3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 4 − IN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-3. 4-4. 4-5. 4-6. 4-7.

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

4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-9. Connecting To Remote 3 Pin Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SECTION 5 − OP OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SECTION 6 − OP OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 6-1. 115 Volt And 230 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SECTION 7 − MA M AINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7-2. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7-3. 7-4. 7-5. 7-6. 7-7.

Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 7-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SECTION 8 − TH THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SECTION 9 − EX EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

TABLE OF CONTENTS SECTION 10-1. 10-2. 10-3. 10-4.

10-5. 10-6. 10-7. 10-8. 10-9.

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

Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Voltage Regulator Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

10-10. Voltage Regulator Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 10-11. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10-12. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10-13. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 10-14. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 11-3. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

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.  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  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.  Only qualified persons should test, maintain, and repair this unit.

STATIC (ESD) can damage PC boards.  Put on grounded wrist strap BEFORE handling boards or parts.  Use proper static-proof bags and boxes to store, move, or ship PC boards.

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

ELECTRIC SHOCK can kill.  Do not touch live electrical parts.  Stop engine before testing or repairing unit unless the procedure specifically requires an energized unit.  Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.

ENGINE EXHAUST GASES can kill.  Do not breathe exhaust fumes.  Use in open, well-ventilated areas, or vent exhaust outside and away from any building air intakes.

 Do not leave live unit unattended.  When testing live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free.

FUEL can cause fire or explosion. SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.  Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

 Stop engine and let it cool off before checking or adding fuel.  Do not add fuel while smoking or if unit is near any sparks or open flames.  Do not overfill tank; clean up any spilled fuel.

MOVING PARTS can cause injury.  Keep away from moving parts such as fans, belts, and rotors.  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.

BATTERY EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery.  Stop engine before disconnecting or connecting battery cables.

 Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

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

 Block flywheel so that it will not turn while working on generator components.

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

 Reinstall panels or guards and close doors when servicing is finished and before starting engine.

FLYING METAL can injure eyes.  Wear safety glasses with side shields or face shield during servicing.  Be careful not to short metal tools, parts, or wires together during testing and servicing.

D302K 3+12

 Do not use welder to charge batteries or jump start vehicles.  Disconnect negative (−) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.  Do not tip battery.  Replace damaged battery.  Flush eyes and skin immediately with water.

TM-4424 Page 1

STEAM AND HOT COOLANT can burn.

TILTING OR TIPPING can cause injury.

 If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if present on unit, instead of radiator.  If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

 Do not put any body part under unit while lifting.  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.  Be careful when working on stator and rotor assemblies.

 Wear safety glasses and gloves and put a rag over radiator cap.  Turn cap slightly and let pressure escape slowly before completely removing cap. MAGNETIC FIELDS can affect pacemakers.  Pacemaker wearers keep away from servicing areas until consulting your doctor.

FALLING UNIT can cause injury.  Use equipment of adequate capacity to lift and support unit and components.  Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.  Securely attach components to lifting equipment.  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.  Allow cooling period before servicing.  Wear protective gloves and clothing when working on a hot engine.  Do not touch hot engine parts bare-handed.

SHOCK HAZARD from testing.  Stop engine before making or changing meter lead connections.  Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.  Read instructions for test equipment.

1-3.

H.F. RADIATION can cause interference.  High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.  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.  Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before starting to weld again.  Do not block or filter airflow to unit.

READ INSTRUCTIONS.  Use Testing Booklet (Part No. 150 853) when servicing this unit.  Consult the Owner’s Manual for welding safety precautions.  Use only genuine replacement parts.  Reinstall injectors and bleed air from fuel system according to engine manual.

California Proposition 65 Warnings

 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:  Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

 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:  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

1

2

3

4

5

6

1

Warning! Watch Out! There are possible hazards as shown by the symbols.

2

Do not smoke and keep matches and flames away from battery. Sparks can cause battery gases to explode. Battery explosion can blind and injure. Wear a face shield. Battery acid can burn skin. Do not spill acid.

3 10

+ −

1

+

11

+

1

4

4

4

−

− 3

3

2

2

7

+

+

−

− S-176 108

8

9

12

5

Read Owner’s Manual.

6 7

Wear rubber gloves. 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

Moving parts, such as fans, rotors, and belts, can cut fingers and hands and cause injury. Keep away from moving parts.

3/96

S-176 106

1

2

3

1


2

Ether will damage engine. Do not use ether as a starting aid.

3 4

Read Owner’s Manual. Use glow plugs for 10−25 seconds to aid starting in cold weather.

4

6/02

D302K 3+12

TM-4424 Page 3

1

1


2

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

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.

4 5

Stop engine before fueling. Do not fuel a hot engine.

6

Use Diesel Fuel only.

6

3/96

1

1


2

Falling equipment can cause serious injury and damage.

3

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.

4

S-176 104

2 TM-4424 Page 4

3

4

3/96

D302K 3+12

1 1

2

2

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.

3

Fuel tank is located inside base.

4

Do not weld on base of unit.

5

Weld only on supplied brackets or bolt unit down.

1


2

Electric shock from wiring can kill.

3

Moving parts, such as fans, rotors, and belts, can cut fingers and hands and cause injury. Keep away from moving parts.

5

3

4

1

2

3

D302K 3+12

TM-4424 Page 5

S-177 571

1

+

2

2 3

+ 3

1

4

Warning! Watch Out! There are possible hazards as shown by the symbols. Read Owner’s Manual. Follow instructions to activate battery.

5

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.

DIESEL

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.

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

s

Read Operator’s Manual

Three Phase

Electrode Connection

Work Connection

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,, 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

G

32 in (813 mm) 35-3/4 in (908 mm) (to top of lift eye)

 Do not exceed tilt angles or engine could be damaged or unit could tip.

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

 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

B

C

30° 20°

H Front Panel End D

30°

20° F

No fuel: 1040 lb (471 kg) w/ fuel: 1139 lb (516 kg)

D302K 3+12

TM-4424 Page 9

3-3. Volt-Ampere Curves A. Stick Mode

100 90 80 S 70 T L 60 O 50 V C 40 D 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 80 S T L 60 O V C 40 D

20 0 0

100

200

300

DC AMPERES C. TIG Mode

100 80

S T L 60 O V C 40 D

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 . R H / L A G . S . U

1.50 1.25 1.00 0.75 0.50 0.25

IDLE

0.00 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

 Exceeding duty cycle can damage unit and void warranty.

Continuous Welding

1000 800 S E R E P M A D L E W

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.

150 300 125 250 S T L O V C A

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  Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

Movement

 Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards.  If unit does not have GFCI receptacles, use GFCI-protected extension cord.

OR

 See Section 4-2 for mounting information. Grounding: Location

OR

1

Equipment Grounding Terminal (On Front Panel)

2 3

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

 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  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

 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

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

4

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

Inadequate support.

 Do not use flexible mounts.

To Bolt Unit In Place:

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  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


D302K 3+12

TM-4424 Page 15

4-4.

Activating The Dry Charge Battery (If Applicable) Remove battery from unit.

5

4 1

1

Eye Protection − Safety Glasses Or Face Shield

2

Rubber Gloves

3 4

Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity)

5

Well

Fill each cell with electrolyte to bottom of well (maximum).

3

 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

 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

 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 shutdown 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  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-

 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  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  Stop engine before connecting to weld output terminals.

Welding Amperes

10 − 60% 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)

 Do not use worn, damaged, undersized, or poorly spliced cables.

* This


chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

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

S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. 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

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.

115 VOLTS AC

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 re start. 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).  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 stop ping 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

 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


Remote On/Off Switch Required − CV Feeder Using Remote

MIG (GMAW) w/Constant Speed Feeder


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  TIG

With Lift-Arc 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


D302K 3+12

TM-4424 Page 25

5-5.

Remote Voltage/Amperage Control

1

1

Remote 3 Pin Receptacle RC13

2

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 f aulty 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.  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

 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  Stop engine.

1

2

3

 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 capac ity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while clean ing 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 ele ment.

Optional

5

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

Clean or replace primary element if dirty (see note above before cleaning). 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.  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  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.  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  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  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

 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  Stop engine and let cool.  After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel.

1 2

Oil Filter Oil Drain Valve And Hose

3

Oil Fill Cap

4

Primary Fuel Filter

5

Secondary Fuel Filter

6

Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and 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. To drain water from fuel system:

6

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:  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.  Properly lift unit and secure in a level position. Use adequate blocks or stands to support unit while draining fuel tank.

5

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  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 condition (shorted rotor), it protects itself by stopping weld output. Check rotor and brushes before replacing PC3.

1

3

4

5

6

2

Circuit Breaker CB1 (Not Shown)

3

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

 When a help code is displayed

HL.P

normally weld output has stopped but generator power output may be okay.

20

 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 dis play.

4

2

HL.P

23

HL.P

24

6

HL.P

25

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 Revo Revolv lvin ing g Fiel Fields ds (Ro (Roto tor) r) 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 ator Win Wind ding ings Supply Supp ly power to exciter, generator power, and weld circuits.

Fuse F1 Current Feedback

4 Fuse F1 Protects exciter windings from overload. 5

Voltage oltage Regu Regulat lator or Boar Board d PC3 PC3

Changes ac output of stator windings to dc to supply excitation current to the exciter revolving field.

1 Engine

6

Circu Circuit it Bre Breake akers rs CB4, CB4, CB5 CB5,, and and CB6 Protect AC receptacles from overload.

AC Rec Recep epta tacl cles es GFC GFCI1 I1,, GFCI GFCI2 2 and RC11 Provide connection points and power for auxiliary equipment.

3φ

Exciter

Revolving Fields (Rotor)

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).

3

2

Stator Windings

d l e W

Generator Power

6 Circuit Breakers CB4, CB5, CB6

7

8 Circu Circuit it Bre Breake akers rs CB7 CB7 and and CB8 CB8 Provide overload protection for 24 and 115 volts ac portion of Remote 14 receptacle RC14.

7 AC Receptacles GFCI1, GFCI2, RC11

115 VAC

9

Filter Filter Boar Board d PC6/R PC6/Rem emote ote Recep Recep-tacles RC13 and RC14 PC6 protects unit from high frequency. RC13 connects remote amperage/voltage control to unit. RC14 connects remote amperage/voltage amperage/voltage and contactor controls to unit. When a remote control is connected to a Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperagecontrol to the remote control. 10 Voltage/ oltage/Amp Amperag erage e Control Control R2 Adjusts weld output amperage or voltage level.

8

9

Circuit Breaker CB7

8 24 VAC Filter Board PC6/Remote Receptacles RC13, RC14

Circuit Breaker CB8

12

11 Process Process/Cont /Contacto actorr Switch Switch R1 Selects weld process and weld output on/off control. +10 VDC Output Command Voltage

TM-4424 Page 38

Control Board PC1

D302K 3+12

12 Contro Controll Boar Board d PC1 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 Control Circuits Weld Current Circuit External Circuits 3φ Power

13 Therm Thermos ostat tat TH1 Thermostat opens and stops all weld output if unit overheats. 14 Meter Meter Boar Board d PC2 PC2 Displays Display s preset and actual (rectified and filtered) values of the weld voltage and amperage. 15 Main Main Rect Rectifi ifier er Changes ac weld current to dc.

18

CC

Works with PC1 (item 12) 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.

20

Stabilizer Z1 16

CV

CC Weld Output Terminal

16 Burde Burden n Resist Resistor or R3 Provides a path for a minimum SCR holding current to flow.

Electrode

17 Hall Hall Devi Device ce HD1 HD1 Provides current feedback signal to PC1.

Burden Resistor R3

15

CV Weld Output Terminal

Capacitor Bank C10

Main Rectifier

18 Stabil Stabilize izerr Z1

20

19

Smooths current.

(filters)

weld

output

19 Capaci Capacitor tor Bank Bank C10 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.

17

20

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. 9-1. Sa Safe fety ty Prec Precau auti tion ons s − Read Before Using This Guide

 WARNING: ELECTRIC SHOCK can kill.  Disconnect input power or stop engine before servicing.  Do not touch live electrical parts.  Do not operate machines with covers removed.  Have only qualified persons install, use, or service equipment.

PART NAME

FUNCTION

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 de device th that st stores el electrical en 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 NON-POL -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 CIRCUIT BREAKER BREAKER A protection protection device device that that breaks breaks a circuit circuit when when current levels exceed its rating. Unlike a fuse that needs to be replaced when blown, a circuit breaker can be reset. CIRCUIT CIRCUIT COMMON COMMON

POLA POLARI RIZE ZED D +

CB1

When many wires are connect connected ed together 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

DIODE

FAN MOTOR

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. A device that allows current to flow in one direction only. Most common use is to change AC to DC.

CT1

OR CT1

FM

D1

This device provides cooling of the internal parts of a welding power source. 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 f eeder 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 t ransformer. 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 f eeder 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.

IL 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 A

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

B

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

IRON CORE

T1

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


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 Section4-9 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 Section5-1). 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

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)

Resistance Values

±10%

a)

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 R12 R13

−

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

Amperage Readings

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

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  Stop engine.

See Section 10-6 for specific values during testing. Voltage readings tolerance ±10%. 1

Filter Board PC6

2

Receptacle RC2

1

2


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  Stop engine.

See Section 10-8 for specific values during testing. Voltage readings tolerance ±10%.

1

1

Main Control Board PC1

2 3

Plug PLG6 Plug PLG7

4

Plug PLG11

4

2 3


803 816

TM-4424 Page 58

D302K 3+12

10-8. Main Control Board PC1 Test Point Values a) Tolerance specified

−

±10%

unless



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


E2

Synchronization signal

E3

Power supply input: +15 volts dc

F1


F2

Voltage feedback: 1 volt dc per 10 arc volts

F3

Power supply input: −15 volts dc

G1


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


H2

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

H3

Circuit common

J1


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


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


C3


D1


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


E3

Gate Pulse to SCR8 with respect to pin PLG11-F3

F1


F2

Gate Pulse to SCR9 with respect to pin PLG11-F1

F3


D302K 3+12

10-9. Voltage Regulator Board PC3 Testing Information  Stop engine.


Voltage Regulator Board PC3

2 3

Receptacle RC1 Receptacle RC2

1

2 3


803 816

D302K 3+12

TM-4424 Page 61

10-10. Voltage Regulator Board PC3 Test Point Values a) Tolerance specified

−

±10%

unless




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


2


3

Not used

4

Not used

5


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  Stop engine.



Meter Display Board PC2

1

803 816 / 214 536

10-12. Meter Display Board PC2 Test Point Values a) Tolerance specified

−

±10%

unless




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  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.  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 servic ing (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

 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).


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  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: 

generator cables from rectifier assembly



generator power leads from terminal strip TE1



engine wiring harness at in-line connector



engine ground strap from base.

1

Use a hoist to evenly lift and remove engine/generatorassembly. 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

 Do not damage stator or rotor windings during this procedure.  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  Stop engine and let cool. Disconnect battery negative ( − ) cable.

 Be sure to follow torque specifications 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)


217 005-A

Circuit Board PC2 (Meter Display)


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  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.

1 2

Engine Exhaust Pipe

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  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.

4 2 1

 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 dur ing 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.  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  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.

6

 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 dur ing 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.  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

90

18

91

86

100 87

83

1−Fig.14-3 98

99

82

97−Fig.14-2 84

81 80

85

89

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

60

69 59 76 57 56 55 54

75 74

42 47

62 58

70−Fig.14-4 77

30

36

35

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 2 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 3 . . . . . . . . . . Figure 14-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 4 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 5 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . 6 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 7 . . . . . . . . . . . . . +213547 . . Panel, Engine Side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 8 . . . . PC1 . . . . 214769 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 10 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . . 218469 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 19 . . . . . . . . . . . . . . 212620 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 22 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 23 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 24 . . . . . . . . . . . . . +213542 . . Cover, Top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . 25 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1 . . . 27 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1 . . . 28 . . . . . . . . . . . . . . 202629 . . Cover, Radiator Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 29 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 30 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 31 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 32 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 33 . . . . . . . . . . . . . . 213633 . . Bracket, Cover Top SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . 34 . . . . . . . . . . . . . . 212624 . . Shroud Adapter, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 35 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 36 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 37 . . . . . . . . . . . . . . 212606 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 39 . . . . . . . . . . . . . +213544 . . Upright, Rear SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 40 . . . . . . . . . . . . . . 220295 . . Bracket,Stiffener (Eff w/LE304607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 41 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 42 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 43 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . . 4 . . . 44 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 45 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 46 . . . . . . . . . . . . . . 176109 . . Label, Caution Using Ether To Aid Engine Etc . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . . . . . . . . . 215269 . . Label, Diesel Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 48 . . . . . . . . . . . . . . 190126 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 49 . . . . . . . . . . . . . +213546 . . Door, Engine Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . 50 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 TM-4424 Page 82

D302K 3+12


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


Dia. Mkgs.

Part No.

Description

Quantity

Figure 14-1. 14-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . 0717 071731 31 . . Washe asherr, Flat Flat .656id .656idx2 x2.2 .250 50od odx. x.18 187t 7t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 89 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 0717 071731 31 . . Washe asherr, Flat Flat .656 .656idx idx2. 2.25 250o 0odx dx.1 .187 87tt Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . 2134 213464 64 . . Brac Bracke ket, t, Batt Batter ery y Loc Locat ator or (In (In Bas Base e − No Not Shown) . . . . . . . . . . . . . . . . . . . . . 1 . . . 90 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 91 . . . . . . . . . . . . . . 213484 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 92 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 93 . . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor /Rectifier Tray) . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Ho Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 94 . . . . . . . . . . . . . +213543 . . Upright, Front SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 95 . . . . . . . . . . . . . . 200795 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 96 . . . . . . . . . . . . . . 213541 . . Panel, Front Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 97 . . . . . . . . . . Figure 14-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 98 . . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . 99 . . . . . . . . . . . . . . 216347 . . Label, Rating Card Code (Provide Serial No. When Ordering) . . . . . . . . . 1 . . 100 . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1 . . 101 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 102 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . . . . . . . . . . . . 215326 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1 + When ordering ordering a component component originall originally y displaying displaying a precautio precautionary nary label, label, the label label should should also be ordered. ordered. * 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 84

D302K 3+12

Eff W/LE185330 And Following  Hardware is common and not available unless listed. 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

27

3

20

40 39 2

26

25

28

21

29

24

38

1

37

22 23

31 33 36

30

32

34 35

803 749

Figure 14-2. Panel, Front w/Components

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 14-2. 14-2. Panel, Front w/Components ( Figure Figure 14-1 Item 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 . . . . . . . . . . . . . . . . 1 Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1 Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1 Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conn, Circ Ms Protective Cap Size 16−16s Metal . . . . . . . . . . . . . . . . . . . . 1 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1 Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1 Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2

TM-4424 Page 85


Dia. Mkgs.

Part No.

Description

Quantity

Figure 14-2. 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

. . . . R C3 . . . . 2 1 4 8 9 9 . . . . . . . . . . . . . . . . 218556 . . . . . . . . . . . . . . . . 214543 . . . . . . . . . . . . . . . . 134201 . . . . . . PC2 . . . . 214660 . . . . . . . R1 . . . . . 2 1 4 7 6 0 . . . . . . . R2 . . . . . 193118 . . . . . . . S4 . . . . . 021467 . . . . . . . S1 . . . . . 207720 . . . . . . . . . . . . . . . . 039047 . . . . . . . . . . . . . . . . 010381 . . . C1 3 , 1 4 , 1 5 . 1 2 8 7 5 0 . . . . . . . . . . . . . . . . 209056 . . . . . . RC11 . . . . 182954 . . ........................ . . . . . . . . . . . . . . 213509 . . . . GFCI1, 2 . . 151981 . . . . C11, C12 . . 217054 . . . . CB4, CB6 . . 093996 . . . . . . CB5 . . . . 203026 . . . . . . G RD . . . . 0830 30 . . . . . . . . . . . . . . . . 010915 . . . . . . . . . . . . . . . . 601836 . . ........................ . . . . . . . . . . . . . . 181169 . . . . . . . . . . . . . . . . 186621 . . . . . . . . . . . . . . . . 180735 . . . . . . . . . . . . . . . . 039046 . . . . FUEL/HM . . 214768 . . . . . . . . . . . . . . . . 021385 . . . . . . . AM . . . . . 118060 . .

Receptacle, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4 Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1 Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Switch, Tgl Spst 3a 250v Off− none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1 Switch, Ignition 3 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1 Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Capacitor tor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 3 Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1 Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1 Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 2 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2 Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2 Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . . 1 Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1 Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Meter, Amp Dc 60−0−60 2.250 Dia High Profile Stainl . . . . . . . . . . . . . . . . 1

♦Optional

+

When ordering ordering a component component originall originally y displaying displaying a precautio precautionary nary label, label, the label label should should also be ordered. ordered.


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2 Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1 Relay, Encl 12vdc Dpst−no 30a 6pin Flange (Prior to LF065150) . . . . . . 1 Relay Assy (Eff w/LF065150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1 Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2

+

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


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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2

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

*Recommended Spare Parts. ♦Optional To maintain the factory original performance of your equipment, use only Manufacturer’s 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 available unless listed.

6 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 )

. . . . . . . . . . . . . . . . . . . . 217081 . . . 1 . . . . . . . . . . . . . . 211984 . . . 2 . . MOD1,2,3 . . 218296 . . . 3 . . MOD4,5,6 . . 218292 . . . 4 . . . . . . . . . . . . . . 212602 . . . 5 . . . . . . . . . . . . . . 212639 . . . 6 . . . . . . . . . . . . . . 212601 . . . 7 . . . . TH1 . . . . 213930 . . . 8 . . . . C1−6 . . . . 215611 . . . 9 . . . C7,8,9 . . . 048420 . . . 10 . . . . . . . . . . . . . . 217085 . . . . . . . . . . . . . . . . . . . . 181853

. . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Switch, Tgl Spdt 6a 125vac On−none−mc Spd Term . . . . . . . . . . . . . . . . . 1 Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1 Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2 Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . . 1 Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Conn, Rect 250 1pin 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1 Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

. . . . . . . . . . . . . . . . . . . . 217002 . . . . . . . . . . PLG2 . . . . 150316 . . . . . . . . . . PLG9 . . . . 214951 . . . . . . . . . . . . . . . . . . . . 214933 . . . . . . . . . . . . . . . . . . . . 214934 . . . . . . . . . . PLG8 . . . . 147992 . . . . . . . . . . PLG6 . . . . 193184 . . . . . . . . . . PLG7 . . . . 193183 . . . . . . . . . . PLG9 . . . . 215261 . . . . . . . . . PLG10 . . . 215262 . . . . . . . . . . . . . . . . . . . . 215265 . . . . . . . . . . . . . . . . . . . . 215343 . . . . . . . . . . PLG5 . . . . 113750 . . . . . . . . . . . . . . . . . . . . 217000 . . . . . . . . . . . . . . . . . . . . 215340 . . . . . . . . . . . . . . . . . . . . 214933

. . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

. . . . . . . . . . . . . . . . . . . . 214984 . . . . . . . . . PLG11 . . . 193183 . . . . . . . . . . . . . . . . . . . . 207716 . . . . . . . . . . . . . . . . . . . . 207718

. . Harness, Rectifier CC/CV (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

TM-4424 Page 90

D302K 3+12

engine driven Miller D302K3-12 Technical Manual

Recommend Documents