Engine Driven Miller D302K3-12 Technical Manual

TM-4424B April 2005
Eff. w/Serial Number LE185330 And

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

and Gouging
Description
Engine Driven Welding Generator

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-9. Connecting To Remote 3 Pin Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 5 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-1. 115 Volt And 230 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-2. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-3. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-5. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-7. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 9 − EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TABLE OF CONTENTS
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . . . . . . . . . 52
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . . . . . . . . 54
10-4. Waveforms For Sections 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-7. Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10-8. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-9. Voltage Regulator Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10-10. Voltage Regulator Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10-11. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-12. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-13. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10-14. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11-3. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SECTION 14 − PARTS LIST FOR LE185330 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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.
This group of symbols means Warning! Watch Out! possible

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

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

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

D Keep away from moving parts such as
fans, belts, and rotors.
D Have only qualified people remove
BATTERY EXPLOSION can BLIND.
guards or covers for maintenance and D Always wear a face shield, rubber gloves, and
troubleshooting as necessary. protective clothing when working on a battery.
D Keep hands, hair, loose clothing, and tools away from mov- D Stop engine before disconnecting or connect-
ing parts. ing battery cables.
D Before working on generator, remove spark plugs or injec- D Do not allow tools to cause sparks when working on a battery.
tors to keep engine from kicking back or starting. D Do not use welder to charge batteries or jump start vehicles.
D Block flywheel so that it will not turn while working on gener- D Observe correct polarity (+ and −) on batteries.
ator components.
D Disconnect negative (−) cable first and connect it last.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face
shield during servicing. D Do not tip battery.
D Be careful not to short metal tools, parts, or D Replace damaged battery.
wires together during testing and servicing. D Flush eyes and skin immediately with water.
D302K 3+12 TM-4424 Page 1

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

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

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from
committee’s judgment, has not demonstrated that exposure to power- operator as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as
examined. Until the final conclusions of the research are reached, you possible.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-4424 Page 2 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.
3 Sparks can cause battery
10 gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 1
+ − 4 4 Battery acid can burn skin. Do
1 not spill acid.
11 + − 5 Read Owner’s Manual.
+ − 6 Wear rubber gloves.
7 Dead battery
8 Engine block
3 2 9 Fully charged battery
2 3
10 Do not connect last negative
7 cable to dead battery − connect
+ − + − instead to engine block.
11 Jumper cables − observe
polarity and make connections
S-176 108
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
8 9 12 shown. 3/96
1 1 Warning! Watch Out! There

2 2 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
S-176 106 3/96
1 Warning! Watch Out! There

2 Ether will damage engine. Do
1 2 3 4 not use ether as a starting aid.
3 Read Owner’s Manual.
4 Use glow plugs for 10−25
seconds to aid starting in cold
weather.
6/02
D302K 3+12 TM-4424 Page 3

2 Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
S-176 230
3/96

2 3 2 Engine fuel plus flames or
sparks can cause fire.
3 Do not smoke while fueling or if
near fuel.
4 Stop engine before fueling.
4 5 Do not fuel a hot engine.
5
6 Use Diesel Fuel only.
3/96
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.
4 Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.
S-176 104
2 3 4 3/96
TM-4424 Page 4 D302K 3+12

1 2
2 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.
3 4

1 2 Electric shock from wiring can
kill.
3 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
2 injury. Keep away from moving
parts.
D302K 3+12 TM-4424 Page 5

1 Remove unit from shipping
S-177 571
crate. Remove Owner’s
1
+
Manual from unit. Follow
instructions to install muffler.
2 Read Owner’s Manual. Read
labels on unit.
2 3 Use Diesel Fuel only, and fill
+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 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 Some symbols are found only on CE products.
Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)
Starting Aid Engine Oil

Battery (Engine) Engine Oil
(Preheat) Pressure
Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)
Certified/Trained
Positive Negative Welding Arc
Mechanic
A Amperes
V Volts Panel/Local Remote
Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature
Stick (SMAW) Constant Current MIG (GMAW)

TIG (GTAW)
Welding (CC) Welding
h s 1
Time Hours Seconds Single Phase
3
Read Operator’s Do Not Switch
Three Phase Circuit Breaker
Manual While Welding
Engine-Driven,
Electrode
Connection
Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz
X Duty Cycle U0 Rated No Load

Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed
n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current
Contactor On Arc Force (Dig) Lift-Arc TIG
TM-4424 Page 8 D302K 3+12

SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications

Maximum
Welding Weld Output Rated Welding Open- Generator Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
400 A, 23 Volts DC,
40% Duty Cycle
20 − 410 A 300 A, 32 Volts DC
CC/DC 60% Duty Cycle
250 A, 30 Volts DC Single-Phase, Kubota 1505 EBG1
100% Duty cycle 10 kVA/kW, 84 A, Water-Cooled,
Water Cooled, 11.5 gal
65
400 A, 23 Volts DC, 120 V AC, Four-Cylinder, (43.5 L)
30% Duty Cycle 60 Hz 20.2 HP Diesel Engine
300 A, 29 Volts DC
CV/DC 14 − 40 V
60% Duty Cycle
250 A, 26.5 Volts DC
100% Duty cycle
3-2. Dimensions, Weights, And Operating Angles

Dimensions
32 in (813 mm) G
Height 35-3/4 in (908 mm)
(to top of lift eye)
26-1/4 in (667 mm) Y Do not exceed tilt angles or engine could
(mtg. brackets turned in) be damaged or unit could tip.
Width Y Do not move or operate unit where it could
28-3/4 in (730 mm) tip.
(mtg. brackets turned out)
Depth 56 in (1422 mm)
A 56 in (1422 mm)
A
B 54 in (1372 mm) B C
C 52 in in (1321 mm)
D 2 in (51 mm)
E 26 in (660 mm) 30°
F 7/8 in (22 mm) 30°
20°
G 27-3/4 in (705 mm) H
Front Panel End 20°
9/16 in (14 mm) Dia.
H
4 Holes
D F
Weight
E
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 The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
100 the welding generator. Curves of all
other settings fall between the
90 curves shown.
80
70
DC VOLTS
60
50
40
30
MIN
20 300 MAX
10
0
0 100 200 300 400 500
DC AMPERES
B. MIG Mode
100
80
DC VOLTS
60
40
20
0
0 100 200 300 400 500
DC AMPERES
C. TIG Mode
100
80
DC VOLTS
60
40
20 MIN 300 MAX
0
0 100 200 300 400 500
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
1.50
U.S. GAL/HR.
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

100% Duty Cycle At 250 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
1000
800
600
WELD AMPERES
500
400
CC
300 CV
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 gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
AC VOLTS
75 150
50 100
25 50
0 0
0 20 40 60 80
AC AMPERES IN 240 V MODE
0 40 80 120 160
AC AMPERES IN 120 V MODE
217 519
Notes MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
TM-4424 Page 12 D302K 3+12

SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Y Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
Movement ble codes.
Y Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Y If unit does not have GFCI re-
ceptacles, use GFCI-protected
OR extension cord.
. See Section 4-2 for mounting in-

formation.
Grounding:
1 Equipment Grounding Terminal
Location (On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
OR OR lated copper wire.
Grounding
1
GND/PE 2
Electrically bond generator frame to

vehicle frame by metal-to-metal contact.
3 Y Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
Airflow Clearance
18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)
18 in
18 in (460 mm)
(460 mm)
install3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274
D302K 3+12 TM-4424 Page 13

4-2. Mounting Welding Generator
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
Y Do not mount unit by sup-
porting the base only at the
four mounting brackets.
Use cross-supports to ade-
2 quately support unit and pre-
vent damage to base.
Mounting Surface:
1 Cross-Supports
OR 2 Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1
3 1/2 in Bolt And Washer
Inadequate support. (Minimum − Not Supplied)
4 3/8-16 x 1 in Screws
(Supplied)
Y Do not use flexible mounts. To Bolt Unit In Place:
Remove hardware securing the
1 four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Using Mounting Brackets Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
Welding Unit In Place

Bolting Unit In Place
3
2
Tools Needed:
9/16 in
Ref install3 6/04 803 274 / 190 250-A / 803 231
TM-4424 Page 14 D302K 3+12

4-3. Installing Exhaust Pipe
Y Stop engine and let cool.
. Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in 803 582 / Ref. 214 777-E
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12 TM-4424 Page 15

4-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection − Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 bottom of well (maximum).
Y Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6 Battery Charger
Y Read and follow all instruc-
2 tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
. When electrolyte is low, add

only distilled water to cells to
maintain proper level.
5 A For 30 Minutes Tools Needed:
OR
+
− rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − 0886
TM-4424 Page 16 D302K 3+12

4-5. Connecting The Battery
. Close door after connecting battery.
Tools Needed:
1/2 in
Y Connect Negative (−) Cable Last.
Ref. 214 777-E / 803 581−D / S-0756-C
Notes
D302K 3+12 TM-4424 Page 17

4-6. Engine Prestart Checks
Check radiator coolant

level when fluid is low in
recovery tank.
Full Full
Diesel
Capacity:
6 qt (5.7 L)
Coolant Recovery Tank
Hot Full
Cold Full
Full
803 581−D
. Check all engine fluids daily. Do not run out of fuel or air will enter fuel sys- freeze to mixture if using the unit in tempera-
tem and cause starting problems. See en- tures below −34° F (−37° C).
Engine must be cold and on a level surface. gine manual to bleed air from fuel system.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if Oil Keep radiator and air intake clean and free
oil pressure is too low or coolant tempera- of dirt.
After fueling, check oil with unit on level sur-
ture is too high.
face. If oil is not up to full mark on dipstick, Y Incorrect engine temperature can
. This unit has a low oil pressure shut- add oil (see maintenance label). damage engine. Do not run engine
down switch. However, some condi- without a properly working thermo-
tions may cause engine damage before Coolant
stat and radiator cap.
the engine shuts down. Check oil level Check coolant level in radiator before start-
often and do not use the oil pressure ing unit the first time. If necessary, add cool-
shutdown system to monitor oil level. ant to radiator until coolant level is at bottom . To improve cold weather starting:
Follow run-in procedure in engine manual. of filler neck.
If unburned fuel and oil collect in exhaust Use Preheat switch (see Section 5-1).
pipe during run-in, see Section 13. Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank Keep battery in good condition. Store
Fuel
until coolant level is between Cold Full and battery in warm area.
Y Do not use gasoline. Gasoline will Hot Full levels. If recovery tank coolant level
damage engine. was low, also check coolant level in radiator. Use fuel formulated for cold weather
The unit is shipped with enough fuel to pre- Add coolant if level is below bottom of radia- (diesel fuel can gel in cold weather).
vent air from entering fuel system. Add fresh tor filler neck. Contact local fuel supplier for fuel in-
diesel fuel before starting (see engine main- formation.
tenance label for fuel specifications). Leave Unit is shipped with an engine coolant mix-
filler neck empty to allow room for ture of water and ethylene glycol base anti- Use correct grade oil for cold weather
expansion. freeze rated to −34° F (−37° C). Add anti- (see Section 7-3).
TM-4424 Page 18 D302K 3+12

4-7. Connecting To Weld Output Terminals
Y Stop engine.
1 Work (−) Weld Output Terminal
2 CV (Wire) Weld Output Terminal
3 CC (Stick/TIG) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode 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 feed-
er 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***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Stop engine before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
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)
2 ea. 2/0 2 ea. 2/0

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

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
* This chart is a general guideline and may not suit all applications. If 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/
REMOTE Amperage control at max.
OUTPUT
CONTROL
C Output to remote control: 0 to

+10 volts dc.
803 580
4-10. Connecting To Remote 14 Receptacle RC14
Socket* Socket Information
A 24 volts ac. Protected by circuit

breaker CB8.
24 VOLTS AC
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.
REMOTE D Remote control circuit common.

OUTPUT
CONTROL E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz

I ac. Protected by circuit breaker
115 VOLTS AC CB7.
Contact closure to I completes

J 115 volt ac contactor control
circuit.
OR
Current feedback: 1 volt per
F 100 amperes.
H Voltage feedback: 1 volt per 10

arc volts.
803 580 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 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
D302K 3+12 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
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 Engine Gauges, Meters, And Lights 9 Process/Contactor Switch
4 Fuel Gauge/Hourmeter
1 Start/Preheat Switch Use gauge to check fuel level or total engine See Section 5-3 for Process/Contactor
operating hours. switch information.
Use switch to start engine and operate glow To check fuel level or engine hours when en-
plug for cold weather operation. gine is not running, turn Start/Preheat switch 10 Voltage/Amperage Control
to Preheat position.
Engine runs at weld/power speed continu- 5 Engine Indicator Light
With Process/Contactor switch in any Stick or
ously. Light goes on and engine stops if engine tem- TIG setting, use control to adjust amperage.
perature exceeds 230° F (110° C) or engine With Process/Contactor switch in any Wire
oil pressure is below 10 psi (69 kPa). (MIG) position, use control to adjust voltage.
Turn switch to Preheat position to operate the
glow plug and heat the combustion chambers . Normal engine temperature is 180 - 203 With Voltage/Amperage Adjust Switch in Re-
before cranking engine (see starting instruc- F (82 - 95 C). Normal oil pressure is 30 mote position, control limits the remote am-
tions following). - 60 psi (207 - 414 kPa). perage in Stick or TIG mode, but has no effect
Y Do not run engine until trouble is in Wire (MIG) modes.
2 Engine Shutdown Switch fixed.
6 Battery Ammeter Weld Meters
Push switch down to stop engine. Use gauge to check amperage output to the
battery. The gauge reads near 0 (zero) when
3 Engine Stop Lever the engine is running. If gauge is at a negative . Weld meters also work in combination to
number, the battery is discharging. display troubleshooting help codes (see
Use lever to stop engine if Engine Shutdown Weld Controls Section 7-10).
switch does not work. 7 Remote 14 Pin Receptacle
8 Remote 3 Pin Receptacle 11 DC Voltmeter
. The Engine Stop lever shuts off the fuel Use receptacles to connect remote controls,
supply. However, the Engine Stop lever wire feeders, and tools. Voltmeter displays preset voltage (MIG weld-
will not stop the engine if the engine can When a remote control is connected to a Re- ing) with contactor off, and actual output volt-
draw fuel-rich air from the surrounding mote receptacle, the Auto Sense Remote fea- age with the contactor on. Voltmeter displays
atmosphere (oil refineries). ture automatically switches voltage/amper- voltage at the weld output terminals, but not
age control to the remote control connected to necessarily the welding arc due to resistance
To Start: that receptacle (see Sections 4-9, 4-10 and of cable and connections.
5-5).
With remote control connected, weld output is To set voltage, turn contactor off and turn Pro-
. If engine does not start, let engine come determined by a combination of front panel cess/Contactor switch to Wire position. Turn
to a complete stop before attempting re- and remote control voltage/amperage set-
start. V/A control until desired voltage is displayed
tings.
on Voltmeter. When welding is finished, volt-
If no remote control is connected to a Remote meter displays weld voltage and then defaults
Above 41 F (5 C): turn Start/Preheat switch receptacle, the front panel Voltage/Amperage to preset voltage.
to Preheat position for 5 seconds and then control adjusts voltage and amperage.
turn switch to Start position. Release Start/
Preheat switch when engine starts. . If remote controls are connected to both 12 DC Ammeter
remote receptacles, remote amperage/
voltage control is only available through
Below 41 F (5 C): the Remote 3 Pin receptacle. However, Ammeter displays preset amperage (Stick
Turn Start/Preheat switch to Preheat position the Remote 14 Pin receptacle still pro- and TIG only) when not welding, and actual
for 15 seconds and then turn switch to Start. vides remote contactor control. output amperage when welding.
Release Start/Preheat switch when engine
starts. . If a remote device connected to Remote
Receptacle RC13 or RC14 is faulty or is To set amperage, turn Process/Contactor
disconnected, the meters display Help 25 switch to Stick or TIG position. Turn V/A con-
To Stop: trol until desired amperage is displayed on
(see Section 7-10). Clear fault by stop-
ping and restarting the unit or by turning Ammeter. When welding is finished, ammeter
Push Engine Shutdown switch down to stop Process/Contactor switch to another displays weld amperage and then defaults to
engine. position. preset amperage.
D302K 3+12 TM-4424 Page 23

5-3. Process/Contactor Switch
1 Process/Contactor Switch
Y Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table be-
low).
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
GTAW With HF Unit, Pulsing Device, Or Re-

Remote On/Off Switch Required −TIG LIft Arc At Remote 14 Receptacle
mote Control
Remote On/Off Switch

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

MIG (GMAW)
Required − CV Feeder At Remote 14 Receptacle
w/Constant Speed Feeder
Using Remote
MIG (GMAW)
Weld Terminals Always On − Wire Electrode Hot
w/Voltage Sensing Feeder
Stick (SMAW),
Weld Terminals Always On − Stick Electrode Hot
Air Carbon Arc (CAC-A) Cutting And Gouging
Weld Terminals Always On − TIG Lift-Arc TIG Lift-Arc (GTAW) Electrode Hot
TM-4424 Page 24 D302K 3+12

5-4. Lift-Arc™ Start Procedure
Lift-Arc t TIG
With Lift-Arct TIG selected, start
arc as follows:
1 TIG Electrode
Lift-Arc Start Method 2 Workpiece

1 2 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
1−2 present before tungsten electrode
“Touch” Seconds 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 be-
ing contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
Do NOT Strike Like A Match! replace the scratch method.
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12 TM-4424 Page 25

5-5. Remote Voltage/Amperage Control
1 Remote 3 Pin Receptacle
RC13
1 2 Remote 14 Pin Receptacle
RC14
Connect optional remote control to
either RC13 or RC14 (see Sections
4-9 and 4-10 and).
2
Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Min = 20 A DC
Max = 205 A DC
OR
Max (205 A DC)
Min (20 A DC)
Connect Remote Set Remote Process (Only If Set V/A Control Adjust Optional Remote Control
Control To Remote Remote On/Off Control Is Mid-Range:
Receptacle RC13 Desired) About 205A
Or RC14
Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)
Min = 20 A DC
Max = About 205 A DC
OR
Max (205 A DC)
Min (20 A DC)
Set V/A Control Adjust Optional Remote Control

Connect Remote Set Remote Process (Only If Mid-Range:
Control To Remote Remote On/Off Control Is About 205 A
Receptacle RC13 Desired)
Or RC14 Ref. 214 777-E / 803 580
TM-4424 Page 26 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
. At least once a month, run engine at Circuit breaker CB5 protects receptacles
GFCI, GFCI2, RC11 and the generator
weld/power speed and press test but-
winding from overload. If CB5 opens, the
2 115 V 20 A AC GFCI ton to verify GFCI is working properly.
receptacles do not work. Place CB5 switch
Receptacle GFCI2
RC11 supplies 60 Hz single-phase power in On position to reset circuit breaker.
3 230 V 50 A AC at weld/power speed. Maximum output
Receptacle RC11 from RC11 is 10 kVA/kW. . Generator power decreases as weld
GFCI1 and GFCI2 supply 60 Hz single- output increases.
phase power at weld/power speed. 4 Circuit Breaker CB4
Combined output of all receptacles is limit-
Maximum output from GFCI1 or GFCI2 is 5 Circuit Breaker CB6 ed to the 10 kVA/kw rating of the generator.
2.4 kVA/kW.
6 Circuit Breaker CB5 EXAMPLE: If 15 A is drawn from each 115
If a ground fault is detected, GFCI Reset V receptacle , only 26 A is available at the
button pops out and receptacle does not CB4 protects GFCI2 and CB6 protects 230 V receptacle:
work. Check for faulty equipment plugged GFCI1 from overload. If a circuit breaker
in receptacle. Press button to reset GFCI opens, the receptacle does not work. Press 2 x (115 V x 15 A) + (230 V x 26 A) =
receptacle. button to reset breaker. 10.0 kVA/kW
D302K 3+12 TM-4424 Page 27

SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Y Stop engine before maintaining.
Recycle engine . See Engine Manual and Maintenance

fluids. 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 FUEL
Wipe Full Check Fluid Drain Water
Up Levels. See WATER From Fuel
Spills. OIL Section 4-6. System.
Full
Every 50 h
Clean And
Clean Air Filter. Tighten
See Section 7-4. Weld
Terminals.
Every 100 h
Check air cleaner Clean And

hoses for cracks Tighten
and loose clamps. Battery
Connections.
Every 250 h
Replace 1/2 in. Check Belt

Unreadable (13 mm) Tension.
Labels.
Check And
Change Oil. See Change Oil Filter. Clean Spark
Section 7-8. See Section 7-8. Arrestor. See
Section 7-5.
TM-4424 Page 28 D302K 3+12

Every 500 h
Repair Or
Replace
Damaged
Cables.
Change Fuel FUEL Drain Sludge

Check Radiator Filters. See From Fuel
Fluid Level. See Section 7-8. SLUDGE Tank. See
Section 4-6. Section 7-8.
Every 1000 h
Blow Out Or
Vacuum Inside. Service Welding
OR Generator Brushes And
During Heavy
Service, Slip Rings. Service More
Clean Monthly. Often In Dirty Conditions.*
Check
Valve
Clearance.*
Every 2000 h
Clean/Set Injectors.*
7-2. Checking Generator Brushes

1 Generator Brush With Spring
Mark and disconnect leads at brush hold-
er 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
Ref 214 777−F / S−0233−A
D302K 3+12 TM-4424 Page 29

7-3. Maintenance Label
TM-4424 Page 30 D302K 3+12

7-4. Servicing Air Cleaner
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element. En-
1 2 3 4 gine damage caused by using a
damaged element is not covered
by the warranty.
. 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
Optional makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Keep nozzle 1 Housing
2 in (51 mm)
from element. 2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
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
Blow Inspect
(if present). Reinstall cap.
Y Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment 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

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
3 covering cleanout hole.
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.
1
Reinstall cleanout plug.
Tools Needed:
5/16 in 803 582 / Ref. 214 777-E
7-6. Servicing Engine Cooling System

1 Radiator Draincock
2 Radiator Cap Cover
Change coolant according to engine
2 manual. Add coolant according to Sec-
tion 4-6).
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec-
essary.
After engine cools, check coolant level
again and add coolant if necessary.
803 581−D / Ref 214 777−F
TM-4424 Page 32 D302K 3+12

7-7. Adjusting Engine Speed

Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine
Engine Speed speed with tachometer or frequen-
(No Load) RPM (Hz) cy meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
1880 (62.6)
Weld/Power Start engine and run until warm.
Maximum
Turn Process/Contactor switch to
Stick − Weld Terminals Always On
position.
1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
. Do not set engine speed higher

than specified.
3 Engine Stop Lever
Use lever to stop engine if Start/
Preheat switch does not work.
3 Y Stop engine.
Close door.
Stop
1
Tools Needed:
803 581−D
D302K 3+12 TM-4424 Page 33

7-8. Servicing Fuel And Lubrication Systems
Y After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter
5 Secondary Fuel Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary fuel filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise. Bleed air from fuel system ac-
cording to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
6 2 See engine manual.
To replace secondary fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
4 3 place filter , reconnect fuel lines,
and reinstall clamps.
To drain sludge from fuel tank:
Y Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
5 Y Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Tools Needed:
1
803 581 / Ref 214 777−E
TM-4424 Page 34 D302K 3+12

7-9. Overload Protection
Y Stop engine.
1 Fuse F1
F1 protects the stator exciter winding
from overload. If F1 opens, weld and
generator power is low or stops en-
tirely.
If F1 continues to open, check volt-
age regulator board PC3.
. If PC3 senses an overload con-

dition (shorted rotor), it protects
itself by stopping weld output.
Check rotor and brushes before
replacing PC3.
2 Circuit Breaker CB1 (Not
Shown)
3 Circuit Breaker CB2
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected. If CB1
continues to open, check fuel sole-
noid FS1, the fuel pump, throttle so-
lenoid TS1, integrated rectifier SR1,
engine alternator, glow plug, and cir-
1 cuit boards PC2 and PC3.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
3 not crank. Press button to reset
breaker. If CB2 continues to open,
check fuel solenoid FS1, the fuel
pump, throttle solenoid TS1, inte-
grated rectifier SR1, and circuit
boards PC2 and PC3.
4 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
5 6 Remote receptacle RC14, and cir-
cuit 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 re-
mote 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 20
normally weld output has
stopped but generator power
output may be okay.
2 . To reset help displays, stop
unit and then restart. See item
6 below to reset Help 25 dis-
HL.P 21 1
play.
Help 20 Display
Indicates a failure of meter display
3
module PC2, or the wiring between
PC2 and main control module PC1.
22
If this display is shown, check PC1,
HL.P PC2, and the wiring between PC1
and PC2.
4 2 Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
HL.P 23
If this display is shown, check TH1.,
and the wiring between TH1 and
PC1.
5 3 Help 22 Display
Indicates the rectifier heat sink has
overheated. If this display is shown,
HL.P 24
check generator cooling system
and/or reduce duty cycle. Keep en-
gine access door closed when run-
6 ning to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting.
HL.P 25
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 con-
nected to Remote Receptacle
RC13 or RC14 may be faulty. Help
25 is also displayed whenever a re-
mote device has been connected to
RC13 or RC14 and then discon-
nected. Clear fault by stopping and
restarting the unit or by turning Pro-
cess/Contactor switch to another
position. If problem continues,
check the remote device, filter
board PC6, and main control mod-
ule 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
2 Revolving Fields (Rotor) Voltage

Regulator
Turn at 1885 rpm maximum for weld and Board PC3
power. The speed and excitation current
of the field coils determine voltages in 4
stator windings.
3 Stator Windings Fuse F1
Supply power to exciter, generator pow-
er, and weld circuits. Current
Feedback
4 Fuse F1
Protects exciter windings from over-
load.
5 Voltage Regulator Board PC3
Changes ac output of stator windings to 1 2 3
dc to supply excitation current to the ex- 3φ
citer revolving field. Revolving Exciter
Engine Fields
Weld
Controls field current in response to (Rotor) Stator Windings
changes in output load.
Generator Power
If PC3 senses an overload condition
(shorted rotor), it protects itself by stop-
ping excitation current (weld and gener-
ator power output stops).
6
6 Circuit Breakers CB4, CB5, and
CB6 Circuit
Breakers
Protect AC receptacles from overload. CB4, CB5, CB6
7 AC Receptacles GFCI1, GFCI2
and RC11 7
Provide connection points and power for AC
auxiliary equipment. Receptacles
GFCI1, GFCI2,
8 Circuit Breakers CB7 and CB8 RC11
Provide overload protection for 24 and
115 volts ac portion of Remote 14 recep- 8
tacle RC14. 9
115 VAC Circuit
9 Filter Board PC6/Remote Recep- Breaker
tacles RC13 and RC14 CB7
PC6 protects unit from high frequency.
RC13 connects remote amperage/vol-
tage control to unit. RC14 connects
remote amperage/voltage and contac-
tor controls to unit.
When a remote control is connected to
a Remote receptacle, the Auto Sense 8
Remote feature automatically switches
Circuit
voltage/amperage control to the remote 24 VAC
Breaker
control.
Filter Board CB8
10 Voltage/Amperage Control R2 PC6/Remote
Adjusts weld output amperage or volt- Receptacles
age level. RC13, RC14 12
11 Process/Contactor Switch R1
Selects weld process and weld output
on/off control.
+10 VDC Output
Command Voltage Control
Board
PC1
TM-4424 Page 38 D302K 3+12

12 Control Board PC1
AC Or DC Control Circuits Controls weld output by changing
main rectifier SCR gate pulses
Weld Current Circuit (conduction times) after comparing
amperage (CC) or voltage (CV)
External Circuits feedback to selected voltage/am-
perage signal.
3φ Power 13 Thermostat TH1
Thermostat opens and stops all
weld output if unit overheats.
14 Meter Board PC2
Displays preset and actual (rectified
and filtered) values of the weld volt-
age and amperage.
15 Main Rectifier
Changes ac weld current to dc.
Works with PC1 (item 12) to con-
trols weld output by changing recti-
fier SCR gate pulses (conduction
times) after comparing voltage (CV)
or amperage (CC) feedback to se-
CC 18 20 lected voltage or amperage signal.
CC Weld 16 Burden Resistor R3
Stabilizer
Z1 Output Provides a path for a minimum SCR
16 Terminal holding current to flow.
CV
Burden 17 Hall Device HD1
Resistor R3
Provides current feedback signal to
Electrode PC1.
18 Stabilizer Z1
15 19 20
Smooths (filters) weld output
CV Weld current.
Main Capacitor
Bank C10 Output 19 Capacitor Bank C10
Rectifier Terminal
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 Work (−) Weld
Output
HD1 Terminal
SCR CC or CV
Gating Voltage Current
Feedback Work
Signals Feedback
10 11 13 14
Voltage/ Process/
Thermostat Meter
Amperage Contactor Board PC2
Control R2 Switch R1 TH1
D302K 3+12 TM-4424 Page 39

SECTION 9 − EXPLANATION OF ELECTRICAL PARTS
elect_parts 7/04
9-1. Safety Precautions − Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.

D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
BATTERY A source of DC voltage. Typically used in +

Engine Driven equipment.
BRUSHES/SLIP Components that allow electrical connections

RINGS between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
CAPACITOR A device that stores electrical energy. Large POLARIZED NON-POL.

capacitors or a “bank” of capacitors can be +
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk” C1 C1
capacitors can be used for HF protection.
CHASSIS The green ground wire of a primary cord is

connected to the machine frame (chassis) for
safety. Also, you may find many “HF bypass”
capacitors connected to chassis to reduce
High Frequency interference. Expect to see
this symbol used numerous times in circuit
diagrams. The picture shown here is from an
Engine Drive where several wires including
the battery are connected to the chassis.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse CB1
that needs to be replaced when blown, a
circuit breaker can be reset.
CIRCUIT COMMON When many wires are connected together,

rather than showing all the “lines” and “dots”,
this symbol may appear on the circuit. Look
for other Circuit Common symbols on a
circuit diagram. For instance, say 10 symbols
are found on a circuit, this means all ten
points are electrically tied together.
TM-4424 Page 40 D302K 3+12

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. W COIL
NRM OPEN
POINTS
CURRENT A transformer that produces an AC voltage CT1

TRANSFORMER used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in OR
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current. CT1
DASHED LINE 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, FM
dashed lines do not conduct electricity. The
picture shown is a combination fan motor and
transformer in one part.
DIODE A device that allows current to flow in one

direction only. Most common use is to D1
change AC to DC.
FAN MOTOR 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 F1
when the current exceeds the fuse rating.
GAS OR WATER These are electromechanical devices used to

SOLENOID start or stop the flow of shielding gas or
(VALVE) water. GS1
OR
WS1
HALL DEVICE Produces a small DC voltage proportional to

the current it is sensing (usually welding HD1
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 TM-4424 Page 41

IGBT A device that is used as an “electronic

switch”. When a signal is applied to the gate C1
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically G1 (B1)
used in “Inverter” designed welding machines
to control the welding output. E1
INTEGRATED An arrangement of four diodes used to +

BRIDGE change AC to DC.
RECTIFIER AC
+
AC AC
−
AC
_
INTEGRATED IC’s often called “chips” provide a complete

CIRCUIT circuit function with inputs and outputs. A
good example would be the “Pulse Width
Modulation” chip used in many wire feeder U1
designs.
JUMPER LINK Usually, the jumper link is a piece of brass

that connects two terminals together. Dashed TE1
lines indicate possible locations for other
jumper links.
LIGHT EMITTING This device usually referred to by its initials

DIODE LED is used to tell you when a particular
D1
circuit is activated. This function is very
helpful for troubleshooting.
MAGNETIC This device usually referred to as a

AMPLIFIER “Mag-Amp” is made up of coil windings and
an iron core similar to a transformer. It
controls a large welding current by varying a
small “control current”.
MA1
METER A measuring device. A “voltmeter” is a good

example. V = voltmeter
V A = ammeter
HM = hour
meter
MOSFET A device that is used as an “electronic D

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
G
to control a relay, the speed of a motor, or
even the output of a welding machine. AS
S
TM-4424 Page 42 D302K 3+12

MOTOR A device that converts electrical energy into

mechanical energy. Typically used to feed M1 = DC
wire in a MIG welding system, or pump
coolant in a recirculating liquid-cooling
system. = AC
M1
OPERATIONAL Usually referred to as an “Op-Amp”, this IC

AMPLIFIER chip is very versatile and widely used on PC
boards. A typical use might be as a +
“comparator”, comparing the command A1
_
signal to the feedback signal allowing the
welding output to be kept constant.
OPTICAL A device that uses “light” to get electrical

COUPLER separation (isolation). This eliminates noise OC1
that might be in one circuit from affecting
another circuit.
PILOT LIGHT A light located on the front panel which

1
indicates if the machine is on or off.
PL
POTENTIOMETER Both devices have a moveable brush that

OR makes contact along a resistor, allowing you
RHEOSTAT to easily change the resistance measured at R1
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator CW = CLOCKWISE
a way to adjust welding parameters such as
wire speed, preflow time, voltage, CCW =COUNTER-
inductance, etc. CLOCKWISE
PLUG A connection device that hangs loose with

wires coming out the back of it. Please note MALE
that the plug terminals can be either male or FEMALE
female.
PLG =
PLG1 LOOSE
RECEPTACLE A connection device that is mounted or fixed.

Just like a plug, the terminals can be either MALE
male or female. FEMALE
RC =
RC1 MOUNTED
RELAY−−COIL AND This is an electromechanical device whose COIL

CONTACTS, contacts change state (the normally open
CR1
NORMALLY OPEN points close and the normally closed points
AND NORMALLY open) when proper voltage is applied to the
CLOSED coil. These contact points in turn may control CR1 CR1
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show NRM OPEN NRM CLOSED
the contact points in the power off state. POINTS POINTS
RESISTOR A device which resists the flow of electric FIXED R1

current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED TAPPED R1
RIBBON CABLE A connection device where the wires are laid

out flat. Usually to connect circuits from one 26-CONDUCTOR
CABLE
PC board to another PC board.
RC54 RC44
D302K 3+12 TM-4424 Page 43

SCR A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current K
G
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
A
control the output to a load such as a welding
arc.
SHUNT A precision low-value resistor typically used

to supply a small voltage to drive an
SHUNT
ammeter.
SNUBBER A device used to absorb voltage spikes,

sometimes found connected across the
points of a relay. SN1
SPARK GAP 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 G
welding.
STABILIZER/ When placed in a DC circuit, the inductor or

REACTOR stabilizer as it is usually called, will oppose
Z1
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 L1
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
SWITCH A mechanical device that completes or SPST SPDT

breaks the path of the current or sends it over
a different path.
A multi-pole switch will use dashed lines to

connect poles. DPST DPDT
SPST = Single Pole Single Throw

SPDT = Single Pole Double Throw
DPST = Double Pole Single Throw
DPDT = Double Pole Double Throw
MOMENTARY A switch that “springs back” to its original

SWITCH position. S1
LIMIT SWITCH A switch mounted in the path of a moving

object and actuated by its passage. NRM OPEN NRM
S1 CLOSED
S1
PUSH BUTTON A switch in which a button must be NRM NRM

SWITCH depressed each time the contacts are to be OPEN CLOSED
opened or closed. PB1 PB1
ROTARY SWITCH A switch in which its shaft must be rotated to

actuate the contacts.
S1 S1
TM-4424 Page 44 D302K 3+12

PRESSURE A change in the pressure of a gas or liquid OPENS CLOSES

SWITCH will actuate this switch. ON ON
INCREASE INCREASE
S1 S1
TEMPERATURE Typically used to protect engines, this switch OPENS CLOSES

SWITCH is actuated by heat. ON ON
INCREASE INCREASE
S1 S1
WATER FLOW A switch that is actuated by the flow of a

SWITCH liquid. Typically used to protect
“water-cooled” torches.
OPENS CLOSES
ON ON
INCREASE INCREASE
S1 S1
TERMINAL A connection point for primary power and the

ASSEMBLY jumper links that are used to match the input TE1
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.
TE1
TERMINAL STRIP An insulated connection point for wires. They 42 42 104 105 74
are used for the ease of making multiple 1T
connections and can be a convenient point A B C D E
for making electrical checks when
troubleshooting. (Notice the “jumper link” 104 105
connecting terminals A and B together.)
THERMISTOR A thermally sensitive resistor. There are two

types of thermistor, PTC (Positive
Temperature Coefficient) and NTC (Negative
Temperature Coefficient). A PTC thermistor’s RT1
resistance will increase as the temperature OR
goes up, where as an NTC thermistor’s TH1
resistance will decrease as the temperature
goes up. Primarily used for “Fan on Demand”
and “Thermal Shutdown” circuits.
THERMOSTAT, This is a switch that closes its normally open

NORMALLY OPEN contacts (or opens its normally closed
AND NORMALLY contacts) when a preset temperature is TP1 TP1
CLOSED reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when NRM OPEN NRM CLOSED
needed and shutting off the output of a
welding power source if it is overheating.
TRANSISTOR Most commonly used as an electronic switch. Q1 C Q1 C

There are two basic types, PNP and NPN.
This refers to their internal design, which B B
determines current flow direction.
E E
NPN PNP
D302K 3+12 TM-4424 Page 45

TRANSFORMER A device that changes AC voltage from one

magnitude to another. Typically used to IRON
reduce high primary voltages to lower T1 CORE
welding voltages.
FERRITE
T1 CORE
AIR
T1 CORE
TRIAC An electronic AC switch. It is turned on by a

gate signal similar to an SCR. Q1
TWISTED WIRE Wires are twisted to prevent “electrical noise”

from interfering with the circuit. A good
example is the red and white gate leads RED
going to an SCR. Typically, these wires are
twisted together to help prevent the SCR WHT
from misfiring.
VARISTOR A protection device whose resistance is

dependent on the voltage applied to it. In
normal operation it has a high resistance; VR1
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.
WIRES WITH When lines (wires) cross on a circuit diagram

CONNECTION 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.
TM-4424 Page 46 D302K 3+12

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
D302K 3+12 TM-4424 Page 47

SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
. See Section 10-2 for test points and
values and Section 14 and following
for parts location.
. Use MILLER Testing Booklet (Part

No. 150 853) when servicing this
unit.
Note Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see
Section 7-10).
A. Welding
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch R1 in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles. On/Off Switch Required position and turn remote contactor on (see Section 4-10).
Reset circuit breaker CB7 or CB8 (see Section 7-9). Check for faulty remote device connected to RC13
or RC14.
Check and secure connections to Remote Control receptacle RC13 or RC14 (see Section 4-9 or 4-10).
Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms ±10%.
Replace R2 if necessary.
Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 7-10).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Reset circuit breaker CB3 (see Section 7-9).
Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator board
PC3. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check
rotor and brushes before replacing PC3.)
Clean slip rings, and install new brushes if necessary (see Section 10-13).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator 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.
essary.
Low open-circuit voltage. Check engine speed, and adjust if necessary.
Check main control board PC1 and connections, and replace PC1 if necessary.
Check SCR’s in main rectifier, and replace if necessary. If any SCR’s are replaced, check capacitors
C1 through C9 for a short or open, and check for proper connections. Replace C1 through C9 if
necessary.
No remote fine amperage control. Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC13 or RC14 (see Section 4-9
or 4-10).
No 24 volt or 115 volt ac output at Re- Reset circuit breaker CB7 (24 volt) or CB8 (115 volt) (see Section 7-9).
mote receptacle RC14.
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble Remedy
No generator power output at ac recep- Reset receptacle circuit breakers (see Section 6-1).
tacles; weld output okay.
Check resistance of generator power windings between leads 91 and 92. Replace stator if
necessary.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
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.)
Clean slip rings, and install new brushes if necessary (see Section 10-13).
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
High output at generator power ac Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 10-9).
receptacles. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
Low output at generator power ac Check engine speed, and adjust if necessary.
receptacles.
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 Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 7-9).
Check engine wiring harness and components.
Check engine wiring harness plug connections.
Check continuity of Engine Start/Preheat switch S1, and replace if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and 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 pump according to engine manual.
Air in fuel system. See engine manual.
Engine hard to start in cold weather. Use Start/Preheat switch S1 (see Section 5-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 7-3).
Check continuity of Start/Preheat switch S1, and replace if necessary.
Check glow plug for proper operation, and replace if necessary.
Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 4-6).
Reset circuit breaker CB1 and/or CB2 (see Section 7-9). Check engine alternator, engine harness,
fuel solenoid FS1, and the fuel pump.
Check continuity of Start/Preheat switch S1, and replace if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Check integrated rectifier SR2, and replace if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 7-4 and 7-8).
See engine manual.
TM-4424 Page 50 D302K 3+12

Trouble Remedy
Battery discharges between uses. Turn Start/Preheat switch S1 off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine uses oil during run-in period; 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
V9,R9 E
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
c) Reference − single arrow: reference to
circuit common (lead 42); double
arrow: reference to points indicated Resistance Values
d) Process/Contactor switch R1 in Weld
Terminals Always On − Stick (Dig-B) a) Tolerance − ±10% unless
position unless noted specified
e) Wiring Connections − see Section 12 b) Condition − 70°F (21°C); cold
machine (no warm-up)
V1 120 − 124 volts ac
c) Wiring Connections − see
V2 120 − 124 volts ac
Section 12
V3 240 − 248 volts ac
d) Stop engine before checking
V4 158 volts ac resistance
V5 24 volts ac
R1 thru R8 Less than 1 ohm
V6 46 volts ac R9 22 ohms
V7 46 volts ac R10 14.2 ohms
V8 46 volts ac R11 Empty fuel tank: 250 ohms
Full tank: 0 ohms
V9 + 61 volts dc
R12 1 ohm
V10 +12 volts dc R13 15.5 ohms
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) Amperage Readings
V14 +5 volts dc a) Tolerance − ±5% unless specified
V15 0 to +5 volts dc from min to max of b) Condition − 70°F (21°C); cold
Voltage/Amperage control R2
machine (no warm-up); no load;
V16 +5 volts dc weld/power rpm unless noted
V17 +41 volts dc with Process/Contactor switch c) Process/Contactor switch R1 in
R1 in Weld Terminals Always On − Stick
Weld Terminals Always On − Stick
position; +20 volts dc with R1 in TIG
position (Dig-B) position unless noted
V18 14 to +40 volts dc with Process/Contactor I1 3.1 amps dc
switch R1 in Weld Terminals Always 4.6 amps at 20 volt, 200 amp load
On−Wire position
V19 Circuit common
V20 1 volt dc per 100 amperes of weld output
V21 − 15 volts dc
V22 +15 volts dc
V23 +12 volts dc
V24 +12 volts dc input with Start/Preheat 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/Con- B. CV/DC Open-Circuit Voltage, Process/Con-

tactor Switch R1 In Weld Terminals Always On tactor Switch R1 In Weld Terminals Always
− Stick (Dig B) Position, Voltage/Amperage On − Wire Position, Voltage/Amperage Con-
Control R2 At Max trol R2 At Max
2 ms 50 V 2 ms 20 V
gnd gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro- D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Weld Terminals cess/Contactor Switch R1 In Weld Terminals
Always On − Stick (Dig B) Position, (Resistive Always On − Wire Position, (Resistive Load)
Load)
5 ms 2 V
gnd
E. SCR Gate Pulses w/Respect To Cathode At No

Load, Process/Contactor Switch R1 In Weld
Terminals Always On − Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max
D302K 3+12 TM-4424 Page 55

10-5. Filter Board PC6 Testing Information
Y Stop engine.
See Section 10-6 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
1 Filter Board PC6
2 Receptacle RC2
803 816 / 217 008
TM-4424 Page 56 D302K 3+12

10-6. Filter Board PC6 Test Point Values
a) Tolerance − ±10% unless

specified
PC6 Voltage Readings b) Reference − to circuit common
(lead 42) unless noted
c) Condition − no load; weld/pow-
er rpm unless noted
d) Process/Contactor switch S6
in Weld Terminals Always On −
Stick position
Receptacle Pin Value

RC2 1 24 volt ac input with respect to pin RC2-5
2 Not used on this model
3 115 volts ac input with respect to pin RC2-5
4 Voltage feedback: 1 volt dc per 10 arc volts
5 Circuit common for 24 and 115 volt ac contactor control circuits
6 Command reference: +10 volt dc input
7 Contactor control circuit: 24 volt ac input with respect to pin RC2-5 and closure on RC14 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
RC3 1 Output to remote control: 0 to +10 volts dc
2 DC input command signal: 0 to +10 volts dc from min to max of remote control with voltage/amperage
control R2 at max
3 Circuit common
D302K 3+12 TM-4424 Page 57

10-7. Main Control Board PC1 Testing Information
Y Stop engine.
1 Main Control Board PC1
2 Plug PLG6
3 Plug PLG7
4 Plug PLG11
4
1
803 816
TM-4424 Page 58 D302K 3+12

10-8. Main Control Board PC1 Test Point Values
specified
er rpm unless noted
d) Process/Contactor switch R1
Stick position

PLG6 A1 Serial data line
A2 +5 volts dc output
A3 CV weld feedback with respect to pin PLG6-B3: same as OCV or load voltage
B2 Command signal input: 0 to +5 volts dc input from min to max of Voltage/Amperage control R2
B3 Voltage feedback reference
C1 Serial data line
C2 Circuit common for Voltage/Amperage control R2
C3 CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage
D2 Frequency to voltage signal: +10 volts dc input at 1860 rpm
D3 Not used on this model
E2 Synchronization signal
E3 Power supply input: +15 volts dc
F1 Not used on this model
F2 Voltage feedback: 1 volt dc per 10 arc volts
F3 Power supply input: −15 volts dc
G1 Not used on this model
G2 Command reference: +10 volt dc input
G3 Shutoff command output (field current); normal condition: 0 volts dc, fault condition: 0.7 volts dc
H1 Not used on this model
H2 Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperage
control
H3 Circuit common
J1 Not used on this model
J3 +10 volts dc output
K1 +5 volts dc output
K3 24 volts ac input
PLG7 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 be-
tween pins A and B
C1 +5 volts dc output
C2 Circuit common
C3 SCR fault signal; +5 volts dc output if any SCR fails
D302K 3+12 TM-4424 Page 59

D1 +2 volts dc input at 77° F
D2 −15 volts dc with respect to pin PLG7-C2
E1 +13 volts dc input
F1 Command common
F2 Weld idle control signal: 0 volts dc output when welding; 3.5 volts dc input when not welding
F3 Current feedback: 0 volts dc input per 100 arc amperes
PLG11 A1 Gate Pulse to SCR1 with respect to pin PLG11-A2
A2 Reference for gate pulse to SCR1
A3 Gate Pulse to SCR2 with respect to pin PLG11-B3
B1 Reference for gate pulse to SCR3
B2 Gate Pulse to SCR3 with respect to pin PLG11-B1
B3 Gate Pulse to SCR2 with respect to pin PLG11-A3
C1 Gate Pulse to SCR4 with respect to pin PLG11-C2
C2 Reference for gate pulse to SCR4
C3 Reference for gate pulse to SCR5
D1 Reference for gate pulse to SCR6
D2 Gate Pulse to SCR6 with respect to pin PLG11-D1
D3 Gate Pulse to SCR5 with respect to pin PLG11-C3
E1 Gate Pulse to SCR7 with respect to pin PLG11-E2
E2 Reference for gate pulse to SCR7
E3 Gate Pulse to SCR8 with respect to pin PLG11-F3
F1 Reference for gate pulse to SCR9
F2 Gate Pulse to SCR9 with respect to pin PLG11-F1
F3 Reference for gate pulse to SCR8
TM-4424 Page 60 D302K 3+12

10-9. Voltage Regulator Board PC3 Testing Information
Y Stop engine.
1 Voltage Regulator Board PC3
2 Receptacle RC1
3 Receptacle RC2
803 816
D302K 3+12 TM-4424 Page 61

10-10. Voltage Regulator Board PC3 Test Point Values

specified
er rpm unless noted
Stick position

RC1 1 14 volts dc input with respect to pin RC1-3
2 +13 volts dc output
3 Circuit common
4 Circuit common
5 Power supply output: +15 volts dc
6 Power supply output: −15 volts dc
7 +10 volts dc input
8 Shutoff command input (field current): normal condition: 0 volts dc, fault condition: 0.7 volts dc
9 Frequency to voltage signal: +10 volts dc output at 1860 rpm
10 SCR fault signal; +5 volts dc input if SCR fails
11 Synchronization signal
12 Not used
RC2 1 120 volts ac input with respect to pin RC1-3
3 Not used
4 Not used
6 +61 volts dc with respect to pin RC2-7
7 +61 volts dc with respect to pin RC2-6
8 158 volts ac with respect to pin RC2-5
9 Not used
10 Not used
11 Not used
12 Not used
TM-4424 Page 62 D302K 3+12

10-11. Meter Display Board PC2 Testing Information
Y Stop engine.
1 Meter Display Board PC2
1
803 816 / 214 536
10-12. Meter Display Board PC2 Test Point Values

specified
er rpm unless noted
Stick position

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 TM-4424 Page 63

10-13. Replacing Brushes And Cleaning Slip Rings

1 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
2 Brush Holder
3 Brush With Spring
4 Brush Holder Cap
5 Brush Holder Retaining Bar
Mark and disconnect leads at caps
and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Y Stop engine.
Install brushes, caps, bar, bracket,
and brush leads. Tighten bracket
hardware.
2
1
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, re-
peat 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
1 procedures in Section 10-1.
Y Stop engine.
2 Allow engine to cool, and then com-
plete pre-operational checks in
table.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.

Test Equipment Needed: Tools Needed:
Check fuel and oil (see Section 4-7).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
803 816
D302K 3+12 TM-4424 Page 65

SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
Y Stop engine and let cool. Dis-
connect 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 en-
gine manifold.
Disconnect fuel line at engine.
. To aid in reassembly, mark leads

before disconnecting. See lead list
summary in Section 12 for connec-
tion information.
Disconnect:
F generator cables from rectifier as-
sembly
F generator power leads from termi-
1 nal strip TE1
F engine wiring harness at in-line
connector
F engine ground strap from base.
Use a hoist to evenly lift and remove
engine/generator assembly.
Go to Section 11-2.
Remove brushes
before removing
endbell or rotor.
803 818
TM-4424 Page 66 D300K 3+12

11-2. Disassembly Of Generator
3
B
14
C 1
Torques:
A 20 ft lb (27 N.m)
B 10 ft lb (14 N.m)
C 60 in lb (7 N.m)
D 30 ft lb ( 41N.m)
803 686
Y Do not damage stator or rotor win- Remove engine and rotor by removing nuts Reconnect fuel line and exhaust pipe. Torque
dings during this procedure. from studs and separating stator from engine engine manifold screws to 30 ft lb (41 N.m).
adapter. With engine properly supported, re-
Y Use hoist and lifting strap to carefully Reinstall radiator and rear upright. Refill ra-
move hardware securing endbell to stator.
remove generator components. diator with coolant (see Section 7-6 and en-
Reassembly Instructions: gine manual).
1 Brushes
Reinstall engine and generator parts as Reconnect all leads. Use cable ties to secure
2 Stator
needed using torque values in table. leads in existing wiring harness and away
3 Endbell from moving and hot parts.
Reinstall brushes in brushholder assembly.
4 Rotor Reconnect negative (−) battery cable. Rein-
Reinstall engine/generator assembly in unit.
stall cover, panels, and doors.
5 Stud Reinstall mounting hardware and torque to 50
ft lb (68 N.m).
Remove brushes from brushholder assembly
before disassembling generator.
D300K 3+12 TM-4424 Page 67

11-3. Replacing Rectifier SCR Modules
Y Stop engine and let cool. Dis-
connect battery negative (−)
cable.
. Be sure to follow torque specifica-

tions in table when installing and
SCR Module Torques: connecting SCR module. Retorque
mounting hardware after four
SCR Mounting Screw SCR Connection Screw Terminal hours.
1 Rectifier Assembly
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m) 45 in lb, ±5 in lb 2 SCR Module
(5 N⋅m, ±0.5 N⋅m)
After four hours re-torque to 3 SCR Connection Screw
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m) 4 SCR Mounting Screw
Remove left side panel. Remove rectifi-
er assembly screws and slowly tilt as-
sembly out.
Remove defective SCR module.
Clean mounting surface where 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 hard-
ware as specified.
Remove protective foam from SCR ter-
minals (if applicable) before connecting
leads.
1 2 3
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.
Circuit Wiring
Model Serial Or Style Number
Diagram Diagram
D302K 3+10 CC/CV Models LE185330 and following 218 546-C See Table 12-1
Circuit Board PC6 LE185330 and following 217 005-A

(HF Filter Board)
Circuit Board PC2 LE185330 and following 214 535-A

(Meter Display)
Notes
Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
D302K 3+12 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

−−−− PLG1 TO G1 70A PLG7 (F2) TO PC5 (J)
−−−− PLG1 TO G2 71A PLG1 (5) TO FUEL LEVEL SENDER
−−−− PLG1 TO K1 80 PC6 − EXIT
−−−− PLG1 TO K2 80A STATOR TO TE1
11A STATOR TO RECT. 81A PLG6 (K3) TO CB8
16A PLG6 (A3) TO R−3 RIGHT 81A STATOR TO CB8
16A SCR’S CV (+) TO C10 (+) 84A GFCI−1 (H) TO CB6
16B SCR CV (+) TO R3 (RIGHT) 84C PLG10 (3) TO #84 STATOR LEAD
17A Z1 TO SCR’S CC (+) 85A GFCI−2 (H) TO CB4
18A Z1 (CV) TO CV OUTPUT STUD 87A PC6 − CB7
19A PLG6 (C3) TO R−3 LEFT 90A STATOR TO TE1 (C)
19A Z1 (CC) TO CC OUTPUT STUD 90A TE1 (C) TO RC11 (WB)
19B Z1 TO R3 (LEFT) 90C GFCI−1 (N) TO TE1 (C)
21A STATOR TO RECT. 90D GFCI−1 (N) TO GFCI−2 (N)
30A PLG6 (B3) TO R−3 CENTER 91A STATOR TO TE1 (B)
30A SCR’S (−) TO C10 (−) 91A TE1 (B) TO CB5
30B C10 (−) TO NEG OUTPUT STUD 91B PLG10 (1) TO #91 STATOR LEAD
30B HEAT SINK (−) TO R3 (CENTER) 91B STATOR TO VR
31A STATOR TO RECT. 91C STATOR TO CB7
40A CR1 (8) TO PLG5 (1) 92A STATOR TO TE1 (A)
40B CR1 (8) TO PLG9 (1) 92A TE1 (A) TO CB5
41A STARTER TO CB1 (BATTERY) 92B PLG10 (2) TO #92 STATOR LEAD
42A GROUND STUD TO TE1 92B STATOR TO VR
42A GROUND TERMINAL TO PLG9 (3) 94A CB5 TO RC11 (X)
42A S2 TO GROUND TERMINAL 94B CB5 TO CB6
42AA GFCI−1 (GRND) TO GROUND STUD ON POWER 95A CB5 TO RC11 (Y)
PANEL 95B CB5 TO CB4
42AB GFCI−2 (GRND) TO GROUND STUD ON POWER 99C PLG10 (4) TO #99 STATOR LEAD
PANEL 100A STATOR TO SPLICE (PC3)
42B GROUND TERMINAL TO PLG5 (2) 100B PLG10 (5) TO STATOR 100A
42B SR2 TO GROUND TERMINAL 101A STATOR TO FUSE 1
42B TE1 TO BASE GROUND 105A PLG10 (6) TO BRUSH
42C FUEL PUMP TO GROUND TERMINAL
106A PLG6 (F3) TO PLG9 (6)
42C GR STUD POWER PANEL TO RC11 (GR)
107A PLG6 (D2) TO PLG9 (9)
42C PC6 TO FRT PANEL GROUND
42C PLG6 (J1) TO EXIT 108A PLG10 (7) TO BRUSH
42D FUEL SENDER GROUND TO GROUND TERMINAL 109A PLG6 (E3) TO PLG9 (5)
42E FUEL SENDER GROUND TO PLG1 (8) 112A PLG6 (E2) TO PLG9 (11)
42F ENGINE BLOCK GROUND TO GROUND TERMINAL 113A PLG6 (H3) TO PLG9 (4)
42G GROUND TERMINAL TO GROUND TERMINAL 114A PLG10 (8) TO F1
42TG T1−5 TO TE−1 117A PLG6 (G3) TO PLG9 (8)
42Y FRONT PANEL GROUND STUD TO TE1 120A PLG7 (E1) TO PLG9 (2)
43A AMP METER (+) TO ALT (B) 121A PLG7 (C3) TO PLG9 (10)
43B CB2 TO CB3 130A PLG6 (J3) TO PLG9 (7)
43C CB2 TO ALT (B) 132A PC6 − CB8
43D S1 (30) TO AMMETER (+) 135A PLG6 (G2) TO PC6 (6)
44A CB1 (AUX) TO AMP METER (−) 135C RC13 (C) TO RC3 (1)
45A CB3 TO CR1 (6) 136A PLG7 (F1) TO PC6 (8)
46A STARTER TO FS1 136C RC13 (A) TO RC3 (3)
47A STARTER TO S1 (50) 137A PLG6 (H2) TO PC6 (9)
47B S1 (50) TO PLG1 (6) 140A PLG7 (F3) TO PC6 (10)
48B CB2 TO CR1 (2) 141A PLG6 (F2) TO PC6 (4)
52A CR1 (4) TO SR1 148A PLG6 (D3) TO PC6 (2)
52B SR1 TO S4 (WIPER) 148C RC13 (B) TO RC3 (2)
53A S4 (NO) TO CR1 (O) 150A PLG7 (B3) TO PC6 (7)
53B CR1 (O) TO BARE 160A PLG7 (B1) TO PLG3 (4)
53C SR2 TO FS1 161A PLG7 (A1) TO PLG3 (5)
53D S4 (NC) TO PLG1 (4) 162A PLG6 (K1) TO PLG3 (6)
53E SR2 TO FUEL PUMP 165A PLG6 (C2) TO PLG2 (1)
53F ALT (IG) TO BARE 166A PLG6 (B2) TO PLG2 (2)
53G SR2 TO BARE 167A PLG6 (A2) TO PLG2 (3)
53H SR2 TO BARE 180A PLG6 (F1) TO EXIT
54A CR1 (1) TO PLG1 (7) 181A PLG6 (G1) TO EXIT
55A S1 (17) TO S1 (19) 182A PLG6 (H1) TO EXIT
55B S1 (17) TO GLOW PLUG 188A PLG7 (C1) TO PLG4 (1)
55C S1 (19) TO SR1 189A PLG7 (D1) TO PLG4 (2)
56A PLG1 (2) TO S2 190A PLG6 (A1) TO PLG5 (3)
57A PLG1 (3) TO S3 191A PLG6 (C1) TO PLG5 (4)
TM-4424 Page 74 D302K 3+12
SECTION 13 − RUN-IN PROCEDURE
run_in1 8/01
13-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, 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
1 run-in.
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 addition-
al engine run-in information.
D302K 3+12 TM-4424 Page 75

13-2. Run-In Procedure Using Load Bank
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
4
from flammables.
2 procedure at less than 20
1 exceed duty cycle or equip-
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor 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.
Set load bank switches and then
3 adjust generator Voltage/Amper-
age control so load equals rated
voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manu-
al).
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 mini-
mum position, then turn off load
bank to remove load. Run engine
several minutes at no load.
Repeat procedure if wetstacking is
present.
S-0683
TM-4424 Page 76 D302K 3+12

13-3. Run-In Procedure Using Resistance Grid
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
6
from flammables.
2 procedure at less than 20
exceed duty cycle or equip-
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 connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
3 5 minutes.
Set grid switches and then adjust
generator Voltage/Amperage con-
trol so load equals rated voltage
and current of the generator (see
nameplate, rating label, or the spec-
4 ifications section in this manual).
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 mini-
mum position, then shut down grid
to remove load. Run engine several
minutes at no load.
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
7 6 14
4
5 15
23
16
102
22
101 17
21
20
19
3−Fig.14-5
92
93 18 90
86 91
100
87
1−Fig.14-3 83
98 99
81
97−Fig.14-2 82
84 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
28 29
26
25 30
27
39
38
33
24 37
32
31 30
35 36
67 34
66
65 40
68
64 63
69 60 42
62 47 41
48 49
59
61 43 46 43
76 58 45
70−Fig.14-4 57 44 50
56
77 75
55
54 51
74 53
71
52
53
73
72
803 748−C
D302K 3+12 TM-4424 Page 81

Item Dia. Part
No. Mkgs. 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
Item Dia. Part
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

Item Dia. Part
Figure 14-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 89 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 213484 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor /Rectifier Tray) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . +213543 . . Upright, Front SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 200795 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 213541 . . Panel, Front Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . Figure 14-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 216347 . . Label, Rating Card Code (Provide Serial No. When Ordering) . . . . . . . . . 1
. . 100 . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 101 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 215326 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4424 Page 84 D302K 3+12


13
12
10 11 14
15
8 16
17
6 18
5
4 19
27
3 26
20 25
40
21 28
39 29
38 24
2
1 37 22
23
30
31
33 32
36
34
35
803 749
Figure 14-2. Panel, Front w/Components

Item Dia. Part
Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 97)
... 1 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . . 108864 . . Conn, Circ Ms Protective Cap Size 16−16s Metal . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
... 7 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . PC6 . . . . 217008 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . CB7, CB8 . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
D302K 3+12 TM-4424 Page 85

Item Dia. Part
Figure 14-2. Panel, Front w/Components (Continued)
... 10 . . . . RC3 . . . . 214899 . . Receptacle, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 11 . . . . . . . . . . . . . . 218556 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
... 14 . . . . PC2 . . . . 214660 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . R1 . . . . . 214760 . . Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1
... 16 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . S1 . . . . . 207720 . . Switch, Ignition 3 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 20 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 21 . C13, 14, 15 . 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 3
... 22 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 23 . . . . RC11 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
... 24 ........................ Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
... 25 . . . . . . . . . . . . . . 213509 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . GFCI1, 2 . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 2
... 27 . . C11, C12 . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 28 . . CB4, CB6 . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
... 29 . . . . CB5 . . . . 203026 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . . 1
... 30 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 33 ........................ Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 35 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 36 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 37 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 38 . . FUEL/HM . . 214768 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 39 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 40 . . . . . AM . . . . . 118060 . . Meter, Amp Dc 60−0−60 2.250 Dia High Profile Stainl . . . . . . . . . . . . . . . . 1
♦Optional
TM-4424 Page 86 D302K 3+12

. Hardware is common and not 4

3
8
9
803 798
Figure 14-3. Control Panel
Item Dia. Part

Figure 14-3. Control Panel (Figure 14-1 Item 1)
... 1 .............. 220981 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
... 3 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . CR1 . . . . 199999 .. Relay, Encl 12vdc Dpst−no 30a 6pin Flange (Prior to LF065150) . . . . . . 1
... 4 . . . . CR1 . . . . 223669 .. Relay Assy (Eff w/LF065150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . SR1, SR2 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . CB2, CB3 . . 083432 .. Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
D302K 3+12 TM-4424 Page 87

5
4
Wirng harnesses are listed at 6
3 7
1
8
9
10
11
12
13
14
18
20 19 16
17 803 771
15
Figure 14-4. Generator

Item Dia. Part
Figure 14-4. Generator (Figure 14-1 Item 70)
... 1 . . . ROTOR . . . 212474 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 193515 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 7 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 8 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 9 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 10 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . STATOR . . 212470 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 160943 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 14 .............. 218552 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 047879 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 161306 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 .............. 126984 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 .............. 005614 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 .............. 125548 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 .............. 158832 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
♦Optional
TM-4424 Page 88 D302K 3+12

available unless listed. 6
1
3
2
10
9
803 685-A
Figure 14-5. Rectifier Assembly
Item Dia. Part

Figure 14-5. Rectifier Assembly (Figure 14-1 Item 3)
.................... 217081 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . MOD1,2,3 . . 218296 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . MOD4,5,6 . . 218292 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .............. 212602 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212639 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 .............. 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . TH1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . C7,8,9 . . . 048420 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D302K 3+12 TM-4424 Page 89
Note 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.
Item Dia. Part
Wiring Harnesses
. . . . . . . . . . . . . . . . . . . . 217141 .. Harness, Engine Kubota (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S4 . . . . 199691 .. Switch, Tgl Spdt 6a 125vac On−none−mc Spd Term . . . . . . . . . . . . . . . . . 1
. . . . . . . . SR1, SR2 . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB1 . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 . 083432 .. Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG1 . . . 214932 .. Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 214933 .. Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . 192168 .. Conn, Rect 250 1pin 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 214934 .. Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 217002 . . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 214951 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG8 . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 215261 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 215262 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 215343 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 214984 . . Harness, Rectifier CC/CV (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
.................... 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB4, CB6 . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
TM-4424 Page 90 D302K 3+12

Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
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TM-4424B April 2005

Eff. w/Serial Number LE185330 And

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting

Engine Driven Welding Generator

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

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.

MOVING PARTS can cause injury.

D302K 3+12 TM-4424 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

2-1. Warning Label Definitions

1 2 3 4 5 6 1 Warning! Watch Out! There

1 1 Warning! Watch Out! There

S-176 106 3/96

1 Warning! Watch Out! There

D302K 3+12 TM-4424 Page 3

1 1 Warning! Watch Out! There

TM-4424 Page 4 D302K 3+12

1 Warning! Watch Out! There

D302K 3+12 TM-4424 Page 5

API CD-MIL L 2104D,

Work like a Pro!

TM-4424 Page 6 D302K 3+12

D302K 3+12 TM-4424 Page 7

NOTE Some symbols are found only on CE products.

Fast (Run, Weld/

Starting Aid Engine Oil

Check Injectors/ Check Valve Protective Earth

Stick (SMAW) Constant Current MIG (GMAW)

X Duty Cycle U0 Rated No Load

Contactor On Arc Force (Dig) Lift-Arc TIG

TM-4424 Page 8 D302K 3+12

3-1. Weld, Power, And Engine Specifications

3-2. Dimensions, Weights, And Operating Angles

D302K 3+12 TM-4424 Page 9

20 MIN 300 MAX

TM-4424 Page 10 D302K 3+12

3-5. Duty Cycle And Overheating

D302K 3+12 TM-4424 Page 11

Notes MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

TM-4424 Page 12 D302K 3+12

. See Section 4-2 for mounting in-

Electrically bond generator frame to

3 Y Bed liners, shipping skids, and some running

D302K 3+12 TM-4424 Page 13

Welding Unit In Place

TM-4424 Page 14 D302K 3+12