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PARTS AND OPERATION MANUAL

MQ POWERWHISPERWELDTM

WELDER/A.C.GENERATOR

Model DAW-500S

Revision #0 (07/19/01)

MULTIQUIP INC. PARTS DEPARTMENT:18910 WILMINGTON AVE. 800-427-1244CARSON, CALIFORNIA 90746 FAX: 800-672-7877310-537-3700 SERVICE DEPARTMENT:800-421-1244 800-835-2551FAX: 310-537-3927 FAX: 310-638-8046E-mail:[email protected] www:multiquip.com

PART No. D6845200104B

DAW-500S WELDER/A.C. GENERATOR PARTS & OPERATION MANUAL REV. #0 (07/19/01)

DAW-500S WELDER/A.C. GENERATOR PARTS & OPERATION MANUAL REV.#0 (07/19/01) PAGE 3

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING

PARTS DEPARTMENT800/427-1244 or 310/537-3700FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

WARRANTY DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

MAIN800/421-1244 or 310/537-3700FAX: 310/537-3927


TABLE OF CONTENTS

Here's How To Get Help ............................................ 3Parts Ordering Procedures ....................................... 5Rules For Safe Operation ...................................... 6-7Operation and Safety Decals ................................. 8-9Specifications .......................................................... 10General Information ................................................ 11Dimensions ............................................................. 12Controls and Indicators ...................................... 13-14Trailer Safety Guidelines ......................................... 15Trailer Specifications .......................................... 16-17Trailer Tires and Suspension ............................. 18-19Trailer Wiring Diagram............................................. 20Installation ............................................................... 21Pre-Setup ........................................................... 22-23Instrumentation ....................................................... 24Load Application ..................................................... 25Welder Operating Instructions ........................... 26-27Welder/Generator Use ....................................... 28-29Engine Operating Instructions ........................... 30-31Maintenance ...................................................... 32-33Generator Wiring Diagram ..................................... 34Engine Wiring Diagram ........................................... 35Troubleshooting Welder .......................................... 36Troubleshooting (Engine) ................................... 37-39Explanation Of Codes in Remarks Section ............. 40Suggested Spare Parts ........................................... 41

MQ Power DAW-500S Welder/AC GeneratorGenerator Assembly .......................................... 42-43Control Panel Assembly ..................................... 44-45Electric Parts Assembly...................................... 46-47Engine and Radiator Assembly .......................... 48-49Battery Assembly ............................................... 50-51Muffler Assembly ............................................... 52-53Fuel Tank Assembly ........................................... 54-55Enclosure Assembly ........................................... 56-57Enclosure (Rubber Seals) .................................. 58-59Name Plate and Decals ..................................... 60-61

Crankcase Assembly ........................................... 62-63Oil Pan Assembly ................................................. 64-65Cylinder Head Assembly ...................................... 66-67Gear Case Assembly ........................................... 68-69Head Cover Assembly ......................................... 70-71Oil Filter Assembly ............................................... 72-73Dipstick and Guide Assembly .............................. 74-75Oil Pump Assembly .............................................. 76-77Main Bearing Case Assembly .............................. 78-79Camshaft and Idle Gear Assembly ...................... 80-81Piston and Camshaft Assembly ........................... 82-83Flywheel Assembly .............................................. 84-85Fuel Camshaft Assembly ..................................... 86-87Engine Stop Lever Assembly ............................... 88-89Stop Solenoid Assembly ...................................... 90-91Injection Pump Assembly ..................................... 92-93Inj. Pump Component Assembly .......................... 94-95Governor Assembly ............................................. 96-97Speed Control Plate Assembly ............................ 98-99Nozzle Holder Assembly .................................. 100-101Nozzle Holder Components Assembly ............ 102-103Fuel Filter Assembly ........................................ 104-105Fuel Pump Assembly ....................................... 106-107Alternator Assembly ......................................... 108-109Alternator Component Assembly ..................... 110-111Starter Assembly ............................................. 112-113Starter Component Assembly .......................... 114-115Oil Switch Assembly ......................................... 116-117Water Flange and Thermostat Assembly ......... 118-119Water Pump Assembly ..................................... 120-121Fan Assembly ................................................... 122-123Valve and Rocker Arm Assembly ..................... 124-125Inlet Manifold Assembly ................................... 126-127Exhaust Manifold Assembly ............................. 128-129Air Cleaner Assembly ....................................... 130-131Hydraulic Pump Assembly ............................... 132-133Glow Plug Assembly ........................................ 134-135Starter Switch Assembly .................................. 136-137Accessories ...................................................... 138-139Terms and Conditions Of Sale Parts .................. 140

NOTE

Specification and partnumber are subject tochange without notice.

KUBOTA D1703-EB ENGINE


PARTS ORDERING PROCEDURES

Get special freight allowanceswhen you order 10 or moreline items via FAX!** UPS Ground Service at no charge for freight PS Third Day Service at one-half of actual freight costNo other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

Earn Extra Discounts whenyou order by FAX!

All parts orders which include complete part numbersand are received by fax qualify for the following extradiscounts:

Number ofline items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Now! Direct TOLL-FREE accessto our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

800/6-PARTS-7 800-672-7877

Dealer account number Dealer name and address Shipping address (if different than billing address) Return fax number Applicable model number Quantity, part number and description of each part Specify preferred method of shipment:

UPS Ground UPS Second Day or Third Day* UPS Next Day* Federal Express Priority One (please provide us with your Federal

Express account number)*

Airborne Express* Truck or parcel post

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Extra Fax Disc

ount

for Domestic U

SA

Dealers Only


RULES FOR SAFE OPERATION

Failure to follow instructions in this manualmay lead to serious injury or even death! Thisequipment is to be operated by trained andqualified personnel only! This equipment isfor industrial use only.

The following safety guidelines should always be used whenoperating the DAW-500S Welder/AC Generator:

GENERAL SAFETY

DO NOT operate or service this equipment beforereading this entire manual.

This equipment should not be operated by personsunder 18 years of age.

NEVER operate this equipment without properprotective clothing that is flame-resistant (wool orleather), welding shield, ventilator, steel-toedboots and other protective devices required bythe job.

Protect others around the welding area with barriers and screens.Warn others not to stare at the welding arc.

NEVER operate this equipment when not feelingwell due to fatigue, illness or taking medicine.

NEVER operate this equipment under theinfluence or drugs or alcohol.

NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damage tothe equipment and/or injury to user may result.

Manufacture does not assume responsibility for any accidentdue to equipment modifications.

Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.

Always check the machine for loosened threads or bolts beforestarting.

Always refuel in a well-ventilated area, away from sparks andopen flames.

Always use extreme caution whenworking with flammable liquids. Whenrefueling, stop the engine and allow itto cool. DO NOT smoke around or nearthe machine. Fire or explosion couldresult from fuel vapors, or if fuel is spilledon a hot engine.

NEVER operate the welder/AC generator in an explosiveatmosphere or near combustible materials. An explosion orfire could result causing severe bodily harm or even death.

Topping-off to filler port is dangerous, as it tends to spill fuel. Wear protective ear muffs or ear plugs if noise level is high.

NEVER touch the hot exhaustmanifold, muffler or cylinder. Allowthese parts to cool before servicingengine or welder/AC generator.

The engine of this welder/AC generator requires an adequatefree flow of cooling air. Never operate the welder/AC generatorin any enclosed or narrow area where free flow of the air is

restricted. If the air flow isrestricted it will cause seriousdamage to the welder/ACgenerator engine and maycause injury to people. Theengine gives off DEADLYcarbon monoxide gas.

High Temperatures Allow the engine to cool before addingfuel or performing service and maintenance functions. Contactwith hot components can cause serious burns.

CAUTION:

DO NOT weld near flammable liquids.


This welder/AC generator is equipped with a ground terminalfor your protection. Always complete the grounding path fromthe welder/AC generator to an external grounding source.

NEVER operate this welder/AC generator, or handle anyelectrical equipment while standing in water, while bare foot,while hands are wet, or in the rain. Dangerous electricalshock could occur causing severe bodily harm or even death.

Arc rays can cause blindness. Always wear protectiveshield when welding.

RULES FOR SAFE OPERATION

This welder/AC generator is a source ofproviding LETHAL high voltages. Neverpermit unqualified personnel-especiallychildren to operate the welder/AC generator.

Emergencies

Always know the location of the nearest fire extinguisherand first aid kit. Know the location of the nearest telephone.Also know the phone numbers of the nearest ambulance,doctor and fire department. This information will be invaluablein the case of an emergency.

Maintenance Safety

NEVER lubricate components or attempt service on a runningmachine.

Always allow the machine a proper amount of time to coolbefore servicing.

Keep the machinery in proper running condition. Fix damage to the machine immediately and always replace

broken parts.

Dispose of hazardous waste properly. Examples of potentiallyhazardous waste are used motor oil, fuel, coolant and fuelfilters.

DO NOT use plastic containers to dispose of hazardouswaste.

DO NOT pour waste, oil, coolant or fuel directly onto theground, down a drain or into any water source.

CAUTION:

Backfeed to a utility system can cause electrocution and/orproperty damage. Do not connect to any building's electricalsystem except through an approved device or after buildingmain switch is opened.

Never use damaged or worn cables when connectingpower tools or equipment to the welder/AC generator.Make sure power connecting cables are securelyconnected to the generators output terminals. Insufficienttightening of the terminal connections may cause damageto the welder/AC generator and electrical shock.

CAUTION:

DO NOT touch or open coolant drain plug,radiator cap, or engine oil drain plug whilethe welder/AC generator is running.Always allow sufficient time for the engineand generator to cool before performingmaintenance.

CAUTION:

CAUTION:

NEVER touch output terminals or electrode duringoperation. This is extremely dangerous. Always stop themachine when contact with the output terminals andwelding electrode.

CAUTION:


OPERATION AND SAFETY DECALS

Machine Safety Decals

The DAW-500S welder/AC generator is equipped with a number of safety decals. These decals are provided for operator safety andmaintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decalsbecome unreadable, replacements can be obtained from your dealer.


OPERATION AND SAFETY DECALS


DAW-500S SPECIFICATIONS

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambientconditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometricreading of 29.92 inches and a temperature of 60 degrees Fahrenheit.

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10 FFahrenheit above the standard temperature of 60 F.

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DAW-500S GENERAL INFORMATION

DAW-500S FAMILIARIZATION

Generator

The MQ Power Model DAW-500S welder/AC generator canprovide 450 amps of welding current when in the CV/DCmode and 350 amps of welding current when in the CC/DCmode.

Control Panel

The control panel is provided with the following:! One GFCI 120 volt receptacle, 20 amp (single-phase)! One 120 volt receptacle, 30 amp (single-phase)! Main Circuit Breaker 125V @25 Amps! Circuit Protector Breaker (GFCI) 120V @20 Amps! Idle Control Switch! Starter Switch! Warning Lamp Unit! Hour Meter! Ground Terminal

Engine Protection System

Engine protection fail safe features are provided in the eventof low oil pressure, high coolant temperature and failure ofthe battery to charge. If any of the above conditions occurwhile operating the welder/AC generator, it will cause acomplete unit shut down.

Battery Charge Indicator

This unit is equipped with a protective device that signalsan indicator and automatically stops the engine when thebattery cannot be charged by the alternator.

Water Temperature Indicator

This unit is equipped with an apparatus that signals anindicator and automatically stops the engine when the coolingwater temperature becomes abnormally high. This apparatuswill not function properly if the machine is operated withless than the proper amount of coolant.

Oil Pressure Warning Indicator

In the event of low oil pressure (engine), this welder/ACgenerator is equipped with an engine protection fail safesystem . If low oil pressure is detected while operating thewelder/AC generator, the engine protection system will shutdown the engine.

If this condition (low oil pressure) should occur, please referto the engine troubleshooting table (page 37) in this manual.

Engine

The DAW-500S is powered by a 4-cycle KUBOTA dieselengine. This engine is designed to meet every performancerequirement for welder/AC generator. Reference Table 1,page 10 for engine specifications.

In keeping with MQ Power's policy of constantly improvingits products, the specifications quoted herein are subject tochange without prior notice.

Figures 2 and 3 (pages 13-14) show the basic controls andindicators for the DAW-500S Welder/AC generator.

Circuit Breakers

To protect the welder/AC generator from an overload, a single-pole, 25 amp, main circuit breaker is provided. In addition asingle pole, 20 amp breaker is provided for the G.F.C.I.receptacle. Make sure to switch both circuit breakers to the"OFF" position prior to starting the engine.

General Inspection Prior to Operation

The DAW-500S utilizes a welder/AC generator that has beenthoroughly inspected and accepted prior to shipment fromthe factory. However, be sure to check for damaged parts orcomponents, or loose nuts and bolts, which could haveoccurred in transit.


Figure 1. DAW-500S Dimensions

DAW-500S DIMENSIONS

Dry Weight: 1,025 lbs.Total Weight: 1,150 lbs.


Figure 2. Controls and Indicators

DAW-500S CONTROLS AND INDICATORS

Figures 2 and 3 show the location of the controls and indicators.The functions of each control or indicator is described belowand on the preceding page.

1. Fuel Gauge Indicates the amount of fuel in the fuel tank.

2. Air Outlet Exhaust Allows engine exhaust to exit thewelder/AC generator into the open air. NEVER block thisopening.

3. Fuel Cap Remove this cap to add fuel. Add only #2diesel fuel. Always keep an adequate amount of fuel in thetank. DO NOT top off. Wipe up any spilled fuel immediately.

4. Lifting Hook Use this hook to lift the welder/ACgenerator.

5. Engine Air Cleaner Prevents dirt and other debris fromentering the fuel system. Lift locking latch on air filtercannister to gain access to filter element.

6. Overflow Bottle Supplies coolant to the radiator whenradiator coolant level is low. Fill to indicated level as shownon bottle.

7. Engine Oil Filler Port Remove this cap to add engineoil. Use only recommended type oil. See table 3, page 16.

8. Coolant Drain Plug Remove this plug to drain coolantfrom the radiator.

9. Oil Drain Plug Remove this plug to drain oil from theengine.

10. Automatic Speed Control Solenoid Automaticallyregulates engine speed.

11. Battery Terminals Connect these terminals to the battery.Always pay close attention to the polarity of the terminalswhen connecting to the battery, RED (positive), and BLACK(negative).

12. Battery Provides +12 VDC power for the welder/ACgenerator. When replacing battery (12V 35 AH) use onlyrecommended type battery.

13. G.F.C.I Ground Terminal Use this terminal to connectexternal equipment grounds so that the GFCI receptaclewill have a ground path.

14. Fuel Tank Holds 6.6 gallons (25 liters) of diesel fuel.


DAW-500S CONTROLS AND INDICATORS

15. Fuel Drain Plug Remove this plug to drain fuel from thefuel tank.

16. Frame Ground Lug Connect a ground strap betweenthis lug and a ground rod. Make sure the ground rod isinserted deep into the ground to provide a good earthground. Consult with local Electrical and Safety Codes forproper connection.

17. Oil Filter Provides oil filtering for the engine.

18. Ignition Switch With key inserted turn clockwise to startengine.

19. Hour Meter Indicates number of hours machine hasbeen in use or hours engine was run.

20. Circuit Protector Circuit Breaker This single pole circuitbreaker provides circuit protection (120V @20 amps) forthe G.F.C.I. receptacle.

21. Receptacle G.F.C.I. This receptacle provides 120 voltsoutput at 20 amps.

22. Receptacle Provides 120 volts output at 25 amps.

23. Welding Output Terminals Connect the welding cableto this terminal. Select the appropriate polarities accordingto the application. See Table 7. ! Low Oil Pressure

! High Water Temperature! Electrical System Is Not Charging Properly! Preheat Indicator

27. Sub-Selector Switch-This switch is used to select type ofwelding and welding voltage needed. This switch will notwork in CC mode.

28. DC Voltmeter- Indicated the amount of voltage used duringwelding in CV mode.

29. DC Ammeter- Indicates the amount of amperage beingused during welding in CC mode.

30. Idle Control Switch Regulates the engine speed whenthe welder/AC generator is under load.

31. Warning Lamp Display Lights red when the followingconditions occur:

Figure 3. Controls and Indicators (con't)

24. Main Circuit Breaker This single-pole circuit breakerprovides circuit protection (125V @25 amps) for the electricparts assembly.

25. Current Control (CC) Voltage Control (CV) AdjustmentKnobs Use these controls to adjust welding current andvoltage.

26. Welding Type (Wire/Stick) Selector Switch (CV/CC) Turn this selector switch to either the CV or CC for welding.DO NOT turn this switch under load.


Explanation of Chart:This section is intended to provide the user with trailer ser-vice and maintenance information. The service and main-tenance guidelines referenced in this section apply a widerange of trailers. Remember periodic inspection of the trailerwill ensure safe towing of the equipment and will preventdamage to the equipment and personal injury.

It is the purpose of this section to cover the major mainte-nance components of the trailer. The following trailer com-ponents will be discussed in this section:

" Brakes" Tires" Lug Nut Torquing" Suspension" Electrical" Brake Troubleshooting Tables

Use the following definitions while reading Table 2.

1. Fuel Cell - Provides an adequate amount of fuel forthe equipment in use. Fuel cells must be empty whentransporting equipment.

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is themaximum number of pounds the trailer can carry, in-cluding the fuel cell (empty).

4. Frame Length - This measurement is from the ballhitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender tofender.

6. Jack Stand - Trailer support device with maximumpound requirement from the tongue of the trailer.

DAW-500S TRAILER-SAFETY GUIDELINES

CAUTION:ALWAYS make sure the trailer is in goodoperating condition. Check the tires forproper inflation and wear. Also check thewheel lug nuts for proper tightness.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches(10,12,14, etc.), and the width in mill imeters(175,185,205, etc.). The tire diameter must match thediameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailersaxle.

11. Tire Rim - Tires are mounted on a tire rim. The tire rimmust match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.Always use a torque wrench to tighten down the lugnuts. See Table 4 and Figure 5 for lug nut tightening andsequence.

13. Axle - Indicates the maximum weight the axle can sup-port in pounds, and the diameter of the axle expressedin inches (see Table 3 on page 17). Please not thatsome trailers have a double axle. This will be shown as2-6000 lbs., meaning two axles with a total weight ca-pacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocktransmitted through the wheels. Types of suspensionused are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle. See page 16 forproper wiring connections.

16. Application - Indicates which units can be employedon a particular trailer.

Specifications may change without notice. Contact MQPower Sales for information of specific trailer to unit.


DAW-500S TRAILER-SPECIFICATIONS

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Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacingthe trailer wheels it is important the wheels, tires, and axleare properly matched.

CAUTION:DO NOT attempt to repair or modify awheel. DO NOT install an inner tube tocorrect a leak through the rim. If therim is cracked, the air pressure in theinner tube may cause pieces of the rim

to explode (break off) with great force and cause seriouseye or bodily injury.

Tire Wear/InflationTire inflation pressure is the most important factor inpreserving tire life. Pressure should be checked cold beforeoperation. DO NOT bleed air from tires when they are hot.Check inflation pressure weekly to insure the maximumtire life and to prevent premature tread wear.Table 2 (Tire Wear Troubleshooting) will help pinpoint thecauses and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removingor installing force fitted parts. Failure tocomply may result in serious injury.

SuspensionThe leaf suspension springs and associated components(Figure 4) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 4.

DAW-500S TRAILER TIRES & SUSPENSION

Figure 4. Suspension Components


Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.2. Torque all lug nuts in sequence. See Figure 5. DO

NOT torque the wheel lug nuts all the way down. Tighteneach lug nut in 3 separate passes as defined by Table5.

3. After first road use, retorque all lug nuts in sequence.Check all wheel lug nuts periodically for continued safeoperation.

NOTE

NEVER use an pneumatic air gun totighten wheel lug nuts.

DAW-500S TRAILER TIRES & SUSPENSION

Figure 5. Lug Nut Tightening Sequence

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SHOULDER TYPESHACKLE BOLT

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NOTE:LIGHTS ARE ORIENTED FROM THE DRIVERS SEAT

DAW-500S TRAILER WIRING DIAGRAMS


DAW-500S INSTALLATION

Outdoor Installation

Install the welder/AC generator in a location where it will notbe exposed to rain or sunshine. Make sure the welder/ACgenerator is on secure level ground so it cannot slide orshift around. Do not operate machine with inclination ofmore than 5 degrees. Also install the welder/AC generatorso the exhaust will not be discharged in the direction ofnearby homes.

The installation site must be relatively free from moistureand dust. All electrical equipment should be protected fromexcessive moisture. Failure to do will result in deteriorationof the insulation, and will result in short circuits.

Foreign materials such as dust, sand, lint and abrasivematerials will cause excessive wear to engine and alternatorparts.

CAUTION :

Pay close attention to ventilation whenoperating the welder/AC generator insidetunnels and caves. The engine exhaustcontains noxious elements.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet away from any wall. Using an exhaust pipewhich is too long or too small can cause excessive backpressure and cause the engine to heat excessively.

Eliminate the danger of deadly carbon monoxide gas.Remember that exhaust fumes from any diesel engine arevery poisonous if discharged in a closed room, but harmlessif allowed to mix with the outside air. If the welder/ACgenerator is installed indoors, you must make provisions forventing the engine exhaust to the outside of the building.


Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but do not overfill. Make sure the welder/AC generatoris level. With the dipstick inserted all the way, but withoutbeing screw into the filler hole, verify that the oil level ismaintained between the two notches (Figure 6) on thedipstick. Use grade CC or higher when refilling. See Table 6for proper selection of engine oil.

Fuel

Fill the fuel tank with clean diesel fuel. Do not fill the tankbeyond capacity.

Pay attention to the fuel tank capacity when replenishingfuel. Refer to the fuel tank capacity listed on page 10Specification Table 1.

The fuel tank cap must be closed tightly after filling. Handlefuel in a safety container. If the container does not have aspout, use a funnel.

CAUTION :Never fill the fuel tank while the engine isrunning or in the dark. Fuel spillage on ahot engine can cause a fire or explosion.If fuel spillage occurs, wipe up the spilledgasoline completely to prevent firehazards.

Coolant

Use only drinkable tap water. If hard water or water withmany impurities is used, the inside of the engine and radiatormay become coated with deposits and cooling efficiencywill be reduced.

An anticorrosion additive added to the water will help preventdeposits and corrosion in the cooling system. See theKubota Engine Operator's Manual for further details.

DAW-500S PRE-SETUP

Figure 6. Engine Oil Dipstick

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DAW-500S PRE-SETUP

Day-to-day addition of coolant is done from theOperation in Freezing WeatherWhen operating in freezing weather, be certain that the properamount of antifreeze has been added. See Table 8 forantifreeze operating temperatures.

Day-to-day addition of coolant orantifreeze is done from the reserve tank. See Table 7 forengine, radiator and reserve tank coolant capacities. Makesure the coolant level in the reserve tank is always betweenthe "H" and the "L" markings.

Cleaning the RadiatorThe radiator may overheat if the fins become overloadedwith dust or debris. Periodically clean the radiator fins withcompressed air. Change the radiator fluid every two yearsl

Fan Belt TensionThe deflection of the fan belt may contribute to overheating,or to insufficient charging of the battery. Inspect and adjustit in accordance with the Kubota Engine Operator'sManual.

The fan belt tension is proper if the fan belt (Figure 7) deflects7 to 9 mm (0.28- to 0.35 in.) when depressed with the thumbas shown in Figure 5 below.

CAUTION :

When adding coolant or antifreeze to theradiator, do not remove the radiator capuntil the unit has completely cooled.

When the antifreeze is mixed withwater, the antifreeze mixing ratio mustbe less than 50%.

NOTE

Air CleanerPeriodic cleaning/replacement is necessary. Inspect it inaccordance with the Kubota Engine Operator's Manual.

BatteryConnect the battery to correct polarity. DO NOT connect inreverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level is notproperly maintained. Add only distilled water whenreplenishment is necessary.

The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68 F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poorcontact may result in poor starting or malfunctions, alwayskeep the terminals firmly tightened. Coating the terminalswith a thin film of grease will help to inhibit corrosion.

Figure 7. Fan Belt Tension

CAUTION :

Never place hands near the belts or fanwhile the welder/AC generator is running.

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DAW-500S INSTRUMENTATION

Power Outlets

The welder/AC generator has the following single-phase 60Hz, 120 volt receptacles.

Single Phase

One Duplex NEMA (GFCI) 5-20R (120V, 20 Amp)

One Twist Lock NEMA L5-30R (120V, 30 Amp)

Main Circuit Breaker (Single-Pole)

This single-pole, 25 amp breaker protects the welder/ACgenerator from short circuiting or overloading from the 60Hz single-phase load.

GFCI Protection Breaker (Single-Pole)

This single-pole, 20 amp breaker protects the GFCIreceptacle from short circuiting or overloading.

CAUTION :When using a combination of dualreceptacles, total load should not exceedthe rated capacity of the welder/ACgenerator set.

Idle Control Switch

The DAW-500S Welder/AC generator is provided with anautomatic idle (engine) control capability for noisesuppression and fuel cost reduction. The automatic idlecontrol feature automatically engages under a no-loadcondition.

When the Idle Control Switch is placed in the ON position,the engine revolutions will be approximately 2000 rpm (low-speed operation). When a load is connected to one of theoutput receptacles, the engine speed will au toma t i ca l l yincrease to about 2800 rpm (high-speed operation) within 10seconds. Conversely, when the load is removed, the enginespeed will automatically drop back down to 2000 rpm within10 seconds.

With AC loads of more than 150W (such as lightingequipment, motor-powered tools, submersible water pumps,etc.), the engine runs at high speed. When a no load conditionis produced, the engine automatically slows down.

Turn the idle control switch to the ON (up) position whenAC loads of more than 200W are connected. Turn the idlecontrol switch to the OFF (down) position when AC loadsof less than 100W or when a magnetic switch is used, or ifvery high quality of welding result is required.

However, when welding in CV Low, the engine will continueto run at a low speed, even when appling AC loads.

GFCI Receptacle

Before connecting a load to the generator's GFCI receptacle,push the "Test Button" on the front of receptacle beforeconnecting the load, to confirm that the receptacle isfunctioning correctly.


DAW-500S LOAD APPLICATION

Single Phase LoadAlways be sure to check the nameplate on the welder/ACgenerator and equipment to insure the wattage, amperageand frequency requirements are satisfactorily supplied bythe welder/AC generator for operating the equipment.

Generally, the wattage listed on the nameplate of theequipment is its rated output. Equipment may require 130150% more wattage than the rating on the nameplate, asthe wattage is influenced by the efficiency, power factor andstarting system of the equipment.

The power factor of this welder/AC generator is 1.0. SeeTable 9 below when connecting loads.

! When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of upto the generating sets rated output (kW) can be used.

! When connecting a fluorescent or mercury lamp, acapacity of up to the generating sets rated output (kW)multiplied by 0.6 can be used.

! When connecting an electric drill or other power tools,pay close attention to the required starting currentcapacity.

CAUTION:Motors and motor-driven equipment drawmuch greater current for starting thanduring operation.

An inadequate size connecting cable which cannot carrythe required load can cause a voltage drop which can burnout the appliance or tool and overheat the cable.

The idle control is operated at minimum load capacity of100W. If the load capacity is less than 100W, change theidle control switch to the "OFF" position.

CAUTION:Before connecting this welder/ACgenerator to any buildings electricalsystem, a licensed electrician must installan isolation (transfer) switch. Serious injuryor death may result without this transferswitch.

When connecting ordinary power tools, a capacity of up tothe generating sets rated output (kW) multiplied by 0.8 canbe used.

NOTEIf wattage is not given on theequipment's name plate, approximatewattage may be determined bymultiplying nameplate voltage by thenameplate amperage.

WATTS = VOLTAGE x AMPERAGE

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Welding Cables and Polarities

Connect the welding cables (Figure 8) to the welder's outputterminals located on the control panel. The output terminalshave (+) and (-) polarities. Select the appropriate polaritiesaccording to the application (See Welding Applications,Table 10).

DAW-500S WELDER OPERATING INSTRUCTIONS

NOTE

ALWAYS attach terminal connectors atthe end of each cable. NEVER connectexposed or frayed wires (Figure 9)directly to the terminals. Exposed wiringmay cause shocks or di-electricbreakdown from poor contact.

Figure 8. Electrode Cable Connection

(Correct)

Figure 9. Electrode Cable Connection

(Incorrect)

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DAW-500S WELDER OPERATING INSTRUCTIONS

CAUTION :

CV MODEThis mode is for use of wire feeders. Use the voltage controlto adjust the feeding speed. See Table 11 for maximumvoltage range in relevant to electrode size.

CV HIGHAdjust the CV Voltage Regulator for welding output voltage,with Main Welding CV/CC Selector Switch turned to the rightside and the Sub Selector Switch to CV HIGH.

Never turn Main or Sub Welding CV/CCSelector Switch while using welder.

CV LOW PositionAdjust the CV Voltage Regulator for welding output voltage,with Main Welding CV/C Selector Switch turned to the rightside and the Sub Selector Switch to the center, CV LOW.

NOTE

The CC Current Regulator will not function in thisposition.

CC Mode (for stick)This mode is for use of welding sticks. Use the currentregulator to adjust the feeding speed. See Table 11 formaximum current range in relevant to electrode size.

CC HIGHAdjust the CC Current Regulator for welding current, withMain Welding DV/CC Selector Switch turned to the right sideand the Sub Welding CV/CC Selector Switch turned to thelower position .

NOTE

The CV Voltage Regulator will not function in thisposition.

CC LOWAdjust the CC Current Regulator for welding current, withMain Welding CV/CC Selector Switch turned to the left side.

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The Sub Selector Switch and CV VoltageRegulator will not function in this mode.

NOTE:

The idle control switch will not function and the enginewill remain on low speed during welding operation inthis mode.


Welding and Auxiliary Outputs

In the position of CV Low, the engine will continue run at alow speed, even if AC load is applied. For this reason, it isrecommended not to use AC output terminal when in thismode of welding.

The welder can supply a welding current of 120 amps, andthe AC generator can supply up to 3 kW of power at 120volts simultaneously.

Ground

The nut and ground terminal on the welder/AC generatorshould always be used to connect to a suitable ground. Theground path should be of #8 size wire.

Connect the terminal of the ground wire between the lockwasher and the nut and tighten the nut fully. Connect theirend of the wire to a suitable ground.

Welding Cable

When welding, use the table below (Table 12) to measurethe optimum amount of voltage and amperes when selectingthe proper welding cable. The relationship between cablelength and sectional area is to keep the line voltage dropwithin 4V.

DAW-500S WELDER/GENERATOR USE

Welding/AC Power

This unit will provide simultaneous use of DC welding powerand AC output power. Use the table below (Table 13) whenselecting electrode size for the amount of AC poweravailable.

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DAW-500S WELDER/GENERATOR USE

Duty Cycle

The welder is rated at 100% duty cycle at 350 amps. DutyCycle refers to the amount of time the user can weld andhow long the machine must rest. The duty cycle dependsupon the welding current being used. Select the appropriateduty cycle from Table 14 to prevent overload.

CAUTION :

FIVE ESSENTIALS FOR PROPERWELDING PROCEDURES

Besides the steady sizzling sound that a correct arcproduces, the shape of the molten pool and the move-ment of the metal at the rear of the pool serve as a guidein checking weld quality. In a correctly made deposit, theripples produced on the bead will be uniform and the beadwill be smooth, with no overlap or undercut.

1. Correct Electrode SizeThe correct choice of electrode size involves consider-ation of a variety of factors. Such as the type, position,and preparation of the joint, the ability of the electrode tocarry high current values without injury to the weld metalor loss of deposition efficiency. The mass of work metaland its ability to maintain its original properties afterwelding, the characteristics of the assembly with refer-ence to effect of stresses set up by heat application, thepracticability of heat treatment before and/or after welding,the specific requirements as to welding quality and thecost of achieving the desired results.

2. Correct CurrentIf current on equipment is too high or too low, you arecertain to be disappointed in your weld. If too high, theelectrode melts too fast and your molten pool is large andirregular. If too low, there is not enough heat to melt thebase metal and your molten pool will be too small, will pileup, and look irregular.

3. Correct Arc LengthIf the arc is too long or voltage too high the metal meltsoff the electrode in large globules which wobble from sideto side as the arc wavers, giving a wide, spattered andirregular beadwith poor fusion between original metal anddeposited metal.

If the arc is too short or voltage too low, there is notenough heat to melt the base metal properly and theelectrode quite often sticks to the work. This gives a high,uneven bead, having irregular ripples and poor fusion.

4. Correct Travel SpeedWhen your speed is too fast: your pool does not last longenough, impurities and gas is locked in. The bead isnarrow and ripples pointed. When speed is too slow: themetal piles up, the bead is high and wide, with a ratherstraight ripple.

5. Correct Electrode AngleThe electrode angle is of particular importance in filletwelding and deep groove welding. Generally speaking,when making a filet weld, the electrode should be held sothat it bisects the angle between the plates and isperpendicular to the line of weld. If under cut occurs in thevertical member lowers the angle of the arc and directsthe arc toward the vertical member.

Always wear welding shield with correctfilter shade when welding. Improper use,or looking directly at the arc will lead toblindness.

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The 450 amp, 60% duty cycle referenced inTable 14 is for CV welding ONLY.

EXAMPLE:

CAUTION :Use protective screens or barriers toprotect others from flash and glare; warnothers not to stare at the welding arc.


5. During winter or when the surrounding air temperature iscold, in situations where a load start is required, turnthe key to the 'HEAT' position, you must wait until thepreheat light goes off.

6. If the engine does not start within 10 seconds after thekey is turned to the 'START' position, wait for about 30seconds and repeat the procedure as described instep 4.

CAUTION:

NEVER turn the key to the 'START'position while the engine is running.

DAW-500S ENGINE OPERATING INSTRUCTIONS

WARNING:

If any diesel spillage occurs, completelywipe up the spilled diesel fuel.

The engine's exhaust contains harmfulemissions. ALWAYS ventilate theexhaust when operating inside tunnels,excavations or buildings. Direct exhaustaway from nearby personnel.

Starting

1. Turn the fuel cock lever to the ON position (Figure 10).

CAUTION:

2. Close doors. Operations with the doors open may causeinsufficient cooling to the unit, and damage may result.

3. Insert the key into the starter switch and turn it to the RUNposition. Check to see the oil pressure and charge lightson the "Warning Lamp Unit " are lit. If either are not lit, checkthe system and wiring (refer to the Kubota EngineOperator's Manual).

4. Turn the key to the 'HEAT' position. When the preheat lightis off, turn the key to the 'START' position to start the engine(Figure 11). As soon as the engine starts, release the key.The key will automatically return to the 'ON' position.

Figure 10. Fuel cock lever set to 'ON' position

Figure 11. Key switch set to 'HEAT'

Before Starting

1. Disconnect the electrical load and switch the main circuitbreaker to the 'OFF ' position.

2. Check the fuel level on the fuel gauge. If the fuel is lowfill the fuel tank with clean, fresh diesel fuel.

3. Check the lubricating oil level. If there is not enoughlubricating oil, fill the crankcase with high grade motoroil. Use a high quality detergent oil classified CC orhigher (See Table 8 on page 23).

4. Check the coolant level in the radiator and subtank.Replenish with antifreeze as necessary. Always maintainthe coolant level between the FULL and LOW markingson the coolant container. Be sure the radiator cap isfastened securely.


7. When the engine starts, the oil pressure light and chargelight should go out. If these lights stay on, immediatelystop the engine and check the system and wiring (refer tothe Kubota Engine Operator's Manual).

8. Let the engine idle for five minutes with the automatic idlecontrol switch in the ON position.

9. Check the engine for abnormal vibrations, noises and oilleakage.

10. Check the generator's output voltage by referring to theDC voltmeter on the control panel.

Shutdown

1. Remove the load from the welder/AC generator, thenplace both the main and GFCI circuit breakers to the"OFF" position.

2. Listen for the engine speed to drop. Run at low speedfor 3-5 minutes.

3. Stop the engine by turning the key to STOP positionand remove the key. Turn the fuel cock lever to theOFF position.

DAW-500S ENGINE OPERATING INSTRUCTIONS


DAW-500S MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Service Daily

If the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber in high fuel consumption.

Air Cleaner

Every 100 hours: The air cleaner used on this unit is a drytype. NEVER apply oil to the air cleaner. If welder/ACgenerator has been used in extreme dusty area, service aircleaner more frequently.

Release the air cleaner retaining clamps (Figure 12) andremove the air cleaner element.

Cleaning the Fuel Strainer

Clean the fuel mesh strainer located under fuel capif itcontains dust or water. Remove dust or water in the strainercap and wash it in gasoline. Securely fasten the fuel strainercap so that fuel will not leak. Check the fuel strainer every200 hours of operation or once a month. If damaged, replacewith P/N 1552143160.

Check Oil Level

Check the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 31, page 39.

Replacing Oil Filter

! Drain oil from engine. Use recyclable container to holdused oil. Replace cartridge with P/N 700032091.

! Detach the oil filter cartridge with a filter wrench.

! Apply a film of oil to the gasket for the cartridge.

! Screw in the cartridge by hand. When the gasket is incontact with the seal surface, tighten the cartridge oneor two more times by hand.

! After the oil cartridge has been replaced, add oilaccording to recommended motor oil (Table 6, page 22).Run the engine for a while and check for leaks beforeadding more oil if needed. Clean excessive oil fromengine.

Replacing Fuel Filter

! Replace the fuel filter cartridge with new one every 200hours or so. Use P/N 1707643010.

Wipe the inside of the air cleaner with a damp cloth andremove all dust and debris that have accumulated insidethe air cleaner body.

Used compressed air to clean air filter element. DO NOTuse more than 99 psi. Blow compressed air from the insidewhile turning the element.

If damaged, replace with P/N 7000011081.

Fuel Addition

Add diesel fuel (the grade may vary according to seasonand locations). Always pour through the mesh filter.

Removing Condensation from the Fuel Tank

After prolonged use, condensation and other impuritiesaccumulate in the bottom of the tank. Occasionally remove

the drain cock and drain the contents. During cold weather,the more empty volume inside the tank, the easier it is forwater to condense. This can be reduced by keeping thetank full as much as possible.Air Removal

If air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure.

To restart after running out of fuel, turn the switch to theON position for 15-30 seconds. Try again, if needed. Thisunit is equipped with an automatic air bleeding system.

Figure 12. Air Cleaner Element


DAW-500S MAINTENANCE

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CAUTION :

Allow engine to cool when flushing outradiator. Flushing the radiator while hotwill damage engine and radiator.

Generator Storage

For storage of the generator for over 30 days, the followingis required:

! Drain the fuel tank completely.

! Completely drain the oil from the crankcase and refillwith fresh oil.

! Clean all external parts of the generator with a cloth.

! Cover the generating set and store in a clean, dry place.

! Disconnect eh battery cable (+) (-) from battery.

! Apply fuel oil thinly over the gasket and hand-tightenthe cartridge into position.

! Vent any air.

Flushing Out Radiator and Replacing Coolant

! Open both cocks located at the crankcase side and atthe lower part of the radiator and drain coolant. Openthe radiator cap while draining. Remove the overflowtank and drain.

! Check hoses for softening and kinks. Check clampsfor signs of leakage.

! Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DONOT clean radiator core with any objects, such as ascrewdriver.

! Tighten both cocks and replace the overflow tank.

! Replace with coolant (see page 40, Table 12 for mixture).

! Close radiator cap tightly.


DAW-500S GENERATOR WIRING DIAGRAM


DAW-500S ENGINE WIRING DIAGRAM


DAW-500S TROUBLESHOOTING (WELDER)

Practically all breakdowns can be prevented by properhandling and maintenance inspections, but in the event of abreakdown, please take a remedial action following the

diagnosis based on the Welder Troubleshooting (Table 15)information shown below . If the problem cannot be remedied,please leave the unit just as it is and consult our company'sbusiness office or service plant.

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?rellortnoCdleiFevitcefeD ."rellortnoCdleiF"ecalpeR


?deepswoL .noitces"deepswoltasniamerenignE"otrefeR

erutamranitiucric-trohsreyaL?gnidniw

.erutamraecalpeR

?gniriwevitcefeD .gniriwriapeR

onsierehttubtublamronsirewopCAegatlovdnatnerruC.ytilibapacgnidlew

.evitarepo-nierastnemtsujda

?remrofsnarttnerrucevitcefeD .3TCro2TC,1TC,remrofsnartecalpeR


?)eR(reifitcerevitcefeD .reifitcerecalpeR?)2Lro1LroLCD(rotcaerevitcefeD .rotcaerecalpeR

fossenkcihtdnahtgneletauqedanI?elbacgnidlew

.elbacgnidlewecalpeR

erutamranitiucric-trohsreyaL?gnidniw

.erutamraecalpeR


?sehctiwsrotcelesevitcefeD .2Sro1SecalpeR

,desuebtonnacrowolootsirewopCA.lamronsignidlewtub

?rekaerbtiucricevitcefeD .rekaerbtiucricecalpeR

gnidniwerutamranitiucric-trohsreyaL?)edisCA(

.erutamraecalpeR



.noosootsegrahcsidyrettaB `?rotalugerenigneevitcefeD .rotalugerecalpeR


?hctiwsnoitingievitcefeD .hctiwsnoitingiecalpeR


DAW-500S TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by properhandling and maintenance inspections, but in the event of abreakdown, please take a remedial action following the

diagnosis based on the Engine and Generator Troubleshooting(Table 16) information shown below and on the proceedingpage. If the problem cannot be remedied, please leave theunit just as it is and consult our company's business officeor service plant.

)1TRAP(GNITOOHSELBUORTENIGNE.61ELBATMOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

ytisocsivhgihylevissecxEwoltalioenigneroleuffo

?erutarepmet.lioenigneroleufdeificepsehtesU

enatecwolhtiwleuF?rebmun .leufdeificepsehtesU

esooloteudkaelleuF?tungniniaterepipnoitcejni .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelCpmupnoitcejnI?gninoitcnuflam .ecalperroriapeR

,tfahsknarcfoeruzieSrednilyc,notsip,tfahsmac

?gniraebrorenil.ecalperroriapeR

morfkaelnoisserpmoC?rednilyc

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzondnagulp

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA




tonsinoituloverenignE.htooms

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

esooloteudkaelleuF?tungniniaterepipnoitcejni .tunnethgiT

pmupnoitcejnI?gninoitcnuflam .ecalperroriapeR

gninepoelzzontcerrocnI?erusserp .tsujdA

rokcutselzzonnoitcejnI?deggolc .ecalperroriapeR

epipwolfrevoleuF?deggolc .naelC

?gninoitcnuflamronrevoG .riapeR

eulbroetihwrehtiE.devresbosisagtsuahxe

?lioenigneevissecxE .leveldeificepsehtotecudeR

nrowrenildnagnirnotsiP?kcutsro .ecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA?noisserpmoctneicifeD .ecnaraelcpottsujdA

yargkradrokcalbrehtiE.devresbosisagtsuahxe

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD

?gnimitnoitcejnitcerrocnI .tsujdAstrapgnivoms'enignE

?gniziesebotmees .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzondnagulp




retratsdnatratsotsliafenignE.setator

?tiucrictaeh-erpnekorB .tiucrictaeh-erpkcehC

?leufoN .leufddA

?gniriwevitcefeD .gniriwkcehC

woltasniamerdnastratsenignE.deeps

?reniartsleufdeggolC .ecalperronaelC

?renaelcriadeggolC .ecalperronaelC

?gniriwdetcennocsiD .gniriwriaperdnakcehC

.nurtonseodretratS ?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

?tuodenrub5FesuF .esufecalpeR

egatlovondnasesirdeepsenignE.ecruosrewopCAnitneserpsi

rewopCAnitneserpegatlovoN?ecruos .)1ER(reifitcerecalpeR


?retemtlovevitcefeD .retemtlovecalpeR

?gniriwdetcennocsiD .gniriwriaperdnakcehC

erutamranitiucric-trohsreyaL?gnidniw .erutamraecalpeR

rewopCAdnasesirdeepsenignEebtonnacrowolootsiegatlov

.desu

?)rotcetorp(rekaerbtiucricevitcefeD .)rotcetorp(rekaerbtiucricecalpeRniseriwnekorb,tiucric-trohsreyaL

?gnidniwerutamra .erutamraecalperroriapeR

enignednasesirdeepsenignE.dedaolrevosmees

?rotanretlaevitcefeD .rotanretlaecalperroriapeR

?gniraebrotanretladegamaD .sgniraebrotanretlaecalpeR

lortnoCeldI"dnastratsenignEenignE.noitisopFFOnisi"hctiwS

egralsahenignednasesirdeeps.sdaolrevO.snoitarbiv

?noitallatsnienignedaB .enignefonoitallatsnitaepeR


sahenignednasesirdeeps.esionlamronba

?strapenigneesooL .senthgitrofstrapenignellakcehC

?rotanretlaevitcefeD esoolrogniraebdegamadrofrotanretlakcehC.stlobgnipmalc

?erusolcneevitcefeD .ssenthgitrofstloberusolcnekcehC


hgihtasniamerdnasesirdeepssihctiwslortnoCeldInehwdeeps

.noitisopNOehtnidecalp

?ecivedlortnoceldievitcefeD .ecivedlortnoceldiecalperroriapeR

?hctiwslortnoceldievitcefeD .hctiwslortnoceldiecalpeR

?dionelosevitcefeD .dionelosecalpeR

?yalerevitcefeD .yalerecalpeR


EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this partsbook.

Items Found In the Remarks Column

Serial Numbers-Where indicated, this indicates a serialnumber range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that thecorresponding part is utilized only with this specific modelnumber or model number variant.

Items Found In the Items Number Column

All parts with same symbol in the number column, *, #, +,

%, or , belong to the same assembly or kit.

Note: If more than one of the same reference number islisted, the last one listed indicates newest (or latest) partavailable.

The contents of this parts catalog aresubject to change without notice.

NOTE


DAW-500S W/KUBOTA D1703-EB DIESELENGINE 1 TO 3 UNITSQty. P/N Description5 ............ 7000011081 .......... AIR FILTER5 ............ 1552143160 .......... FUEL FILTER5 ............ 7000032091 .......... OIL FILTER2 ............ 1711297010 .......... FAN BELT1 ............ 3741059110 .......... STARTER SWITCH5 ............ 3741055151 .......... IGNITION KEY2 ............ 1584139010 .......... OIL SENDING UNIT1 ............ D6312500803 ....... RADIATOR HOSE (UPPER)1 ............ D6312500713 ....... RADIATOR HOSE (LOWER)1 ............ 0810105900 .......... FUEL CAP1 ............ 0602200467 .......... EMERGENCY UNIT1 ............ 0601842464 .......... RESISTOR1 ............ 0601807454 .......... MAIN CIRCUIT BREAKER1 ............ 1982639003 .......... SOLENOID, ROTARY4 ............ 1907765510 .......... GLOW PLUG2 ............ 1554383040 .......... SWITCH, WATER TEMP.1 ............ 0602201378 .......... REGULATOR2 ............ 0601821391 .......... RECTIFIER1 ............ 0601803071 .......... CV/CC SELECTOR SWITCH2 ............ D1233000004 ....... OUTPUT TERMINAL2 ............ 0801880004 .......... INSULATOR WASHER4 ............ 0039510000 .......... HEX NUT4 ............ 0045110000 .......... LOCK WASHER4 ............ 0042710000 .......... PLAIN WASHER2 ............ 0000000002 .......... WING NUT1 ............ D9925800104 ....... CONTROL UNIT1 ............ D9925800184 ....... CONTROL UNIT

DAW-500S SUGGESTED SPARE PARTS


DAW-500S GENERATOR ASSY.

GENERATOR ASSY.


DAW-500S GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS1 D6110000202 ROTOR ASSY. 12 0340010045 HEX. HEAD BOLT 63 030210250 LOCK WASHER ..........................6 .............. REPLACES 00425100004 D6130200103 STATOR ASSY. 15 0012110120 HEX. HEAD BOLT 66 030210250 LOCK WASHER ..........................6 .............. REPLACES 00425100007 031110160 PLAIN WASHER .........................6 .............. REPLACES 00412100008 D6153400102 COVER 19 D6153300113 GROMMET 2


DAW-500S CONTROL PANEL ASSY.

CONTROL PANEL ASSY.


DAW-500S CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS1 D6225000603 CONTROL PANEL 12 0021806030 MACHINE SCREW 53 0601803071 WELDING MAIN SELECTOR ........................... 1 ............ SK2533MS4 8705945004 SEAL 15 0016906016 HEX. HEAD BOLT 36 0601830704 WELDING SUB SELECTOR ............................. 1 ............ S7B7 0601840214 RHEOSTAT (CURRENT AND VOLT. REG.) ....... 2 ............ RV24YN20SB5025KOHM8 0601840103 KNOB 29 0023304008 SET SCREW 210 0601800387 DC VOLTMETER ............................................... 1 ............ DCF50~100V11 0601800179 DC AMMETER .................................................. 1 ............ DCF50~750A/6mA12 0602103098 PILOT OPERATING LAMP 1

0601810248 BULB 113 0601807454 CIRCUIT BREAKER ......................................... 1 ............ KM51B25A14 3011816004 CIRCUIT BREAKER BAND SET ...................... 1 ............ S1B15 0027404010 MACHINE SCREW 216 0601830771 IDLE CONTROL SWITCH 117 3741059110 STARTER SWITCH ........................................... 1 ............ REPLACES 060210005918 0601810523 INDICATOR ASSY. 1

0601810830 BULB 419 0602125055 FUEL GAUGE 120 0601800682 HOUR METER 121 D6235400014 SET BOARD, OUTPUT TERMINAL 122 D6235100004 OUTPUT TERMINAL, WELDING 223 000000000 2 WING NUT ........................................................ 4 ............ REPLACES 080188400424 0039312000 HEX. NUT ......................................................... 4 ............ REPLACES 003951200025 0040012000 LOCK WASHER 426 0041412000 PLAIN WASHER 827 D6235500214 RUBBER SEAL 128 0021106020 MACHINE SCREW 129 0601825115 SURGE FILTER 130 0601811031 RECEPTACLE................................................... 1 ............ REPLACES 060181103531 0601812597 RECEPTACLE................................................... 1 ............ REPLACES 060181259832 0601826150 CONDENSER 133 0027404015 MACHINE SCREW 4

0038704000 HEX. NUT 434 0601806420 CIRCUIT PROTECTOR 135 0021003005 MACHINE SCREW 236 0601815109 GROUND TERMINAL 137 D6238100514 COVER, OUTPUT TERMINAL 138 D6238400404 RUBBER SEAL 239 0805088004 STAY RUBBER 240 011206020 HEX. HEAD BOLT............................................. 1 ............ REPLACES 0017106020

0017106000 HEX. NUT 141 011206020 HEX. HEAD BOLT............................................. 1 ............ REPLACES 001710602042 0017106016 HEX. HEAD BOLT 1


DAW-500S ELECTRIC PARTS (1) ASSY.

ELECTRIC PARTS (1) ASSY.




NO PART NO PART NAME QTY. REMARKS

1 D6353600133 SET PANEL, ELEC. PARTS...... 12 0017406016 HEX.HEAD BOLT 43 0601842464 RESISTOR 14 0027104016 MACHINE SCREW 25 0601827619 RELAY ...................................... 1 ........... G7L2ABUBDC12V6 0027104016 MACHINE SCREW 27 0601821391 RECTIFIER ............................... 1 ........... DF100BA40; REPLACES 06018213598 0027105016 MACHINE SCREW 29 8701899004 FUSE BOX ................................ 1 ........... FB6PS

0601806642 FUSE, 5A 40601806643 FUSE, 15A 20601806644 FUSE, 30A 2

10 0027105020 MACHINE SCREW 211 0602200467 EMERGENCY UNIT .................. 1 ........... 174626060112 0027106025 MACHINE SCREW 413 1569465990 LAMP TIMER ............................ 1 ........... REPLACES 0602201273 AND156946599214 0027105016 MACHINE SCREW 115 0601823707 RELAY ...................................... 1 ........... ACA3213CA1DC12VN;

REPLACES 060182452716 0027105016 MACHINE SCREW 117 0601824525 RELAY ...................................... 1 ........... ACA22136CAIBDC12VN18 0027105016 MACHINE SCREW 119 0601815759 TERMINAL BOARD .................. 1 ........... KT206P

D9522000104 DECAL; SYMBOL MARK 120 0027105025 MACHINE SCREW 221 0601823204 RECTIFIER ............................... 1 ........... S5VB6022 0027103016 MACHINE SCREW 123 0601806640 FUSE, 65A 1




NO PART NO PART NAME QTY. REMARKS1 D6215000413 BOX, ELECT. PARTS ................. 1 ......... UP TO S/N5428475

D6215000423 BOX, ELECT. PARTS ................. 1 ......... S/N5428476~2 D9925800104 DC CONTROL UNIT ASSY. ....... 1 ......... CA503 D9925800184 AC CONTROL UNIT ASSY. ....... 1 ......... CA414 0221900245 RUBBER SEAL 15 011206020 HEX. HEAD BOLT ...................... 8 ......... REPLACES 00169060206 D6215400214 COVER ...................................... 1 ......... UP TO S/N5428475

D4515400224 COVER ...................................... 1 ......... S/N5428476~7 0017106016 HEX. HEAD BOLT 48 0017106016 HEX. HEAD BOLT 69 D6485400504 AIR DUCT 110 0017106016 HEX. HEAD BOLT 411 D6485500303 BRACKET 112 0017106016 HEX. HEAD BOLT 513 D6265500303 DC REACTOR ............................ 1 ......... L214 D6265500403 AC REACTOR ............................ 1 ......... L315 0017106016 HEX. HEAD BOLT 816 D6262700614 COVER 117 0017106016 HEX. HEAD BOLT 418 D6262600204 BRACKET, ROT. SOLENOID 119 011008020 HEX. HEAD BOLT ...................... 2 ......... REPLACES 001710802020 1982639003 ROTARY SOLENOID .................. 1 ......... REPLACES 179015020321 D6388100104 ARM SOLENOID 122 011606025 HEX. HEAD BOLT ...................... 1 ......... REPLACES 0010106025

020106050 HEX. NUT .................................. 1 ......... REPLACES 003000600023 0050403020 SPRING PIN 124 0207006000 HEX. NUT 125 D6356300104 GOVERNOR ROD 126 8702151004 GOVERNOR ROD 127 1552154004 SCREW JOIINT 128 0031008000 HEX. NUT 129 0039308000 HEX. NUT .................................. 1 ......... REPLACES 003650800030 031108160 PLAIN WASHER ........................ 1 ......... REPLACES 0041208000

0605010503 SNAP PIN 131 952404470 PLAIN WASHER ........................ 1 ......... REPLACES 0041206000

505015300 SNAP PIN .................................. 1 ......... REPLACES 060501050232 8511864601A PLATE ........................................ 1 ......... REPLACES 851186460433 0017106016 HEX. HEAD BOLT 5


DAW-500S ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.


DAW-500S ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS1 D692520034 ENGINE ........................................ 1 ............ KUBOTA D17031-1 7000032091 CARTRIDGE, OIL FILTER ........... 1 ............ REPLACES 06020411732 D6305200104 ENGINE FOOT 13 D6305200004 ENGINE FOOT 14 D6133100104 ENGINE FOOT 15 D6133100004 ENGINE FOOT 16 012212025 HEX. HEAD BOLT ......................... 7 ............ REPLACES 00124120257 0012410025 HEX. HEAD BOLT 98 7605419004A RUBBER SUSPENSION .............. 2 ............ REPLACES 76054190049 7725419004 RUBBER SUSPENSION 210 0207010000 HEX. HEAD BOLT 411 0602012730 RADIATOR.................................... 1 ............ 4324221318920

0602011064 RADIDATOR CAP 112 D6312100624 BRACKET, RADIATOR 113 0017106016 HEX. HEAD BOLT 214 D6312600304 RUBBER MOUNT 215 D6312200213 FAN GUARD 116 0017106016 HEX. HEAD BOLT 517 D6312500803 RADIATOR HOSE 118 D6312500713 RADIATOR HOSE 119 0605515134 HOSE BAND 220 0605515016 HOSE BAND 221 0602046262 AIR CLEANER .............................. 1 ............ IK3111T012

7000011081 ELEMENT, AIR CLEANER ........... 1 ............ REPLACES 1540111081 AND 060204637222 1538111250 BAND, AIR CLEANER .................. 1 ............ REPLACES 060204057323 011208025 HEX. HEAD BOLT ......................... 1 ............ REPLACES 001710802524 D6485500214 BRACKET, AIR CLEANER ........... 1 ............ UP TO S/N5421717

D6485500224 BRACKET, AIR CLEANER ........... 1 ............ S/N5421718~25 011008020 HEX. HEAD BOLT 2 ............ REPLACES 001710802026 0017106016 HEX. HEAD BOLT 227 D6375100613 HOSE, AIR CLEANER .................. 1 ............ UP TO S/N5421717

D6375100623 HOSE, AIR CLEANER .................. 1 ............ S/N5421718~28 D6375100714 HOSE, AIR CLEANER .................. 1 ............ UP TO S/N5421717

D6375100724 HOSE, AIR CLEANER .................. 1 ............ S/N5421718~29 0605515027 HOSE BAND 130 0605515001 HOSE BAND 231 1502025004 DRAIN JOINT 132 0602021193 PACKING 133 1502025103C DRAIN JOINT ............................... 1 ............ REPLACES 150202510334 0802011104 PLUG 235 0150000018 O RING 236 0017106016 HEX. HEAD BOLT 437 0192200550 DRAIN HOSE 138 0605515158 HOSE BAND 239 1622014103 DRAIN JOINT 140 0199900700 DRAIN HOSE 141 0199900600 DRAIN HOSE 142 0605515094 HOSE BAND 443 0802081403 RESERVE TANK 144 0802081104 CAP, RESERVE TANK 145 0199100215 HOSE 146 8702082004 BRACKET, RESERVE TANK 147 011606025 HEX. HEAD BOLT ......................... 1 ............ REPLACES 001710602548 0017106016 HEX. HEAD BOLT 249 0199900500 HOSE 150 0605515094 HOSE BAND 2


DAW-500S BATTERY ASSY.

BATTERY ASSY.


DAW-500S BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS1 0167306531 BATTERY .................................... 1 ........ 65D31R2 7612251004 BATTERY SHEET 13 D6345200004 BATTERY BAND 14 1742251004 BATTERY BOLT 25 0037806000 WING NUT 26 0040006000 LOCK WASHER 27 952404470 PLAIN WASHER ......................... 2 ........ REPLACES 00412060008 0602220310 TERMINAL ASSY. ...................... 1 ........ NO 9P9 0602220311 TERMINAL ASSY. ...................... 1 ........ NO. 9N10 2845040414 TERMINAL CAP ......................... 1 ........ TC7R; REPLACES 0602220600


DAW-500S MUFFLER ASSY.

MUFFLER ASSY.


DAW-500S MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS1 D6332000322 MUFFLER 12 0017108020 HEX. HEAD BOLT 43 D6335000523 EXHAUST PIPE 14 1526312370 GASKET .................................... 1 ......... REPLACES 06023201535 1502336004 GASKET 16 0207008000 HEX. NUT 47 0017108035 HEX. HEAD BOLT 28 0130012000 ELBOW JOINT 1


DAW-500S FUEL TANK ASSY.

FUEL TANK ASSY.


DAW-500S FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS1 B6365000423 FUEL TANK 11-1 0810105900 CAP, FUEL TANK ....................... 1 ......... REPLACES 08101058002 E1924300164 SENDER, FUEL GAUGE 13 0022905015 MACHINE SCREW 54 D6365300613 BRACKET, FUEL TANK 15 0017108020 HEX. HEAD BOLT 46 1555527004 TANK SHEET 27 D6492700104 RUBBER SEAL 18 D6365200104 TANK BAND 29 D6365300504 PAD, TANK BAND 410 0017106016 HEX. HEAD BOLT 211 0207208000 HEX. NUT 212 1615511204 RUBBER SEAL 113 7812014003 DRAIN JOINT 114 0802011104 PLUG 115 0150000018 O RING ...................................... 2 ......... AP1816 0017106016 HEX. HEAD BOLT 217 0199900750 DRAIN HOSE 118 0605515094 HOSE BAND 219 1707643010 FUEL FILTER ............................. 1 ......... REPLACES 0602042077

1552143160 ELEMENT, FUEL FILTER .......... 1 ......... REPLACES 060204217420 0017108035 HEX. HEAD BOLT 221 0605513152 SUCTION HOSE ........................ 1 ......... 096618030022 0966180180 SUCTION HOSE ........................ 1 ......... REPLACES 060551311623 0605514064 RETURN HOSE ......................... 1 ......... 096614028024 0605514022 RETURN HOSE ......................... 1 ......... 096614017025 0605515179 HOSE BAND .............................. 4 ......... 143014275326 1024442320 HOSE BAND .............................. 4 ......... REPLACES 0605515072


DAW-500S ENCLOSURE ASSY.

ENCLOSURE ASSY


DAW-500S ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO PART NO PART NAME QTY. REMARKS1 D6415000722 BASE 1

D6492100104 RUBBER SHEET 11-1 0221700150 RUBBER SEAL 21-2 0221700365 RUBBER SEAL 22 D6415100104 FLOOR PANEL 23 0017106016 HEX. HEAD BOLT 164 D6455200603 SPLASHER PANEL 15 D6455200713 SPLASHER PANEL 16 D6415500003 GUIDE 27 0017106016 HEX. HEAD BOLT 168 D6425000832 FRONT FRAME 18-1 0221900410 RUBBER SEAL 29 0601850262 GROMMET 110 0017106016 HEX .HEAD BOLT 311 011008020 HEX .HEAD BOLT ......................2 ......... REPLACES 001710802012 D6425200314 COVER, FRONT FRAME 113 0017106016 HEX. HEAD BOLT 1014 D6435300823 HANGER 115 D6435300923 HANGER 116 012212030 HEX. HEAD BOLT.......................4 ......... REPLACES 001711203017 012010030 HEX. HEAD BOLT.......................4 ......... REPLACES 001711003018 D6445000632 REAR FRAME 119 011008020 HEX. HEAD BOLT.......................4 ......... REPLACES 001710802020 D6445300824 COVER, REAR FRAME 121 0017106016 HEX. HEAD BOLT 1022 D6445200113 DOOR, REAR FRAME 122-1 0226900785 EDGE COVER 123 0810014704 PIN 224 0080200004 SNAP RING 225 0601851613 STOPPER 226 D6465000722 ROOF PANEL .............................1 ......... UP TO S/N5421717

D6465000732 ROOF PANEL .............................1 ......... S/N5421718~27 0017106016 HEX. HEAD BOLT 1728 D6465400204 COVER 129 0017106016 HEX. HEAD BOLT 230 D6455001513 SIDE DOOR 131 D6455001433 SIDE DOOR 132 B9114000002 DOOR HANDLE 233 0021806016 MACHINE SCREW 134 0810014704 PIN 435 0080200004 SNAP RING 436 8705164004 DOOR STAY 237 7835088004 COLLAR 238 011208025 HEX. HEAD BOLT.......................2 ......... REPLACES 0017108025


DAW-500S ENCLOSURE (RUBBER SEALS)

ENCLOSURE (RUBBER SEALS)


ENCLOSURE (RUBBER SEALS)

NO PART NO PART NAME QTY. REMARKS

DAW-500S ENCLOSURE (RUBBER SEALS)

1 0228800530 RUBBER SEAL 42 0221900125 RUBBER SEAL 43 0221600100 RUBBER SEAL 44 0221900410 RUBBER SEAL 25 0228800870 RUBBER SEAL 26 0228300730 RUBBER SEAL 17 0228300330 RUBBER SEAL 28 0228300755 RUBBER SEAL 19 0228300700 RUBBER SEAL 1


DAW-500S NAMEPLATE AND DECALS

NAMEPLATE AND DECALS


DAW-500S NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

NO PART NO PART NAME

Welder Generators DAW500S Rev 0 Manual DataId 18254 Version 1

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Transcript of Welder Generators DAW500S Rev 0 Manual DataId 18254 Version 1