Multiquip DAW500S User Manual

PARTS AND OPERA TION MANUAL

MQ POWER

TM

WHISPERWELD

WELDER/A.C.GENERATOR

Model DAW-500S

© COPYRIGHT 2001, MULTIQUIP INC.

PART No. D6845200104B

Revision #0 (07/19/01)

MUL TIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail]

SERVICE DEPARTMENT:

• www:multiquip.com

PAGE 2 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

MAIN

800/421-1244 or 310/537-3700
FAX: [phone]

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

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Parts Ordering Procedures ....................................... 5

Rules For Safe Operation ...................................... 6-7

Operation and Safety Decals ................................. 8-9

Specifications .......................................................... 10

General Information ................................................ 11

Dimensions ............................................................. 12

Controls and Indicators ...................................... 13-14

Trailer Safety Guidelines ......................................... 15

Trailer Specifications .......................................... 16-17

Trailer Tires and Suspension ............................. 18-19

Trailer Wiring Diagram............................................. 20

Installation ............................................................... 21

Pre-Setup ........................................................... 22-23

Instrumentation ....................................................... 24

Load Application ..................................................... 25

Welder Operating Instructions ........................... 26-27

Welder/Generator Use ....................................... 28-29

Engine Operating Instructions ........................... 30-31

Maintenance ...................................................... 32-33

Generator Wiring Diagram ..................................... 34

Engine Wiring Diagram ........................................... 35

Troubleshooting Welder .......................................... 36

Troubleshooting (Engine) ................................... 37-39

Explanation Of Codes in Remarks Section ............. 40

Suggested Spare Parts ........................................... 41

MQ Power DAW-500S —
Welder/AC Generator

Generator Assembly .......................................... 42-43

Control Panel Assembly ..................................... 44-45

Electric Parts Assembly...................................... 46-47

Engine and Radiator Assembly .......................... 48-49

Battery Assembly ............................................... 50-51

Muffler Assembly ............................................... 52-53

Fuel Tank Assembly ........................................... 54-55

Enclosure Assembly........................................... 56-57

Enclosure (Rubber Seals).................................. 58-59

Name Plate and Decals ..................................... 60-61

NOTE

Specification and part
number are subject to
change without notice.

KUBOTA D1703-EB ENGINE

Crankcase Assembly ........................................... 62-63

Oil Pan Assembly ................................................. 64-65

Cylinder Head Assembly ......................................66-67

Gear Case Assembly ........................................... 68-69

Head Cover Assembly .........................................70-71

Oil Filter Assembly ...............................................72-73

Dipstick and Guide Assembly .............................. 74-75

Oil Pump Assembly ..............................................76-77

Main Bearing Case Assembly ..............................78-79

Camshaft and Idle Gear Assembly ......................80-81

Piston and Camshaft Assembly ...........................82-83

Flywheel Assembly .............................................. 84-85

Fuel Camshaft Assembly ..................................... 86-87

Engine Stop Lever Assembly ...............................88-89

Stop Solenoid Assembly ...................................... 90-91

Injection Pump Assembly..................................... 92-93

Inj. Pump Component Assembly .......................... 94-95

Governor Assembly ............................................. 96-97

Speed Control Plate Assembly ............................ 98-99

Nozzle Holder Assembly ..................................100-101

Nozzle Holder Components Assembly ............ 102-103

Fuel Filter Assembly ........................................ 104-105

Fuel Pump Assembly .......................................106-107

Alternator Assembly .........................................108-109

Alternator Component Assembly .....................110-111

Starter Assembly .............................................112-113

Starter Component Assembly ..........................114-115

Oil Switch Assembly .........................................116-117

Water Flange and Thermostat Assembly .........118-119

Water Pump Assembly .....................................120-121

Fan Assembly................................................... 122-123

Valve and Rocker Arm Assembly .....................124-125

Inlet Manifold Assembly ................................... 126-127

Exhaust Manifold Assembly .............................128-129

Air Cleaner Assembly....................................... 130-131

Hydraulic Pump Assembly ............................... 132-133

Glow Plug Assembly ........................................ 134-135

Starter Switch Assembly ..................................136-137

Accessories ...................................................... 138-139

Terms and Conditions Of Sale — Parts .................. 140

PAGE 4 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

PARTS ORDERING PROCEDURES

■■

■ 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.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:

Number of
line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Get special freight allowances
when you order 10 or more
line items via FAX!**

■■

■ UPS Ground Service at no charge for freight

■■

■■

■ PS Third Day Service at one-half of actual freight cost

■■

No 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.

Extra Fax Discount

for Domestic USA

Dealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

CAUTION:

Failure to follow instructions in this manual
may lead to serious injury or even death! This
equipment is to be operated by trained and

qualified personnel only! This equipment is
for industrial use only.

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

GENERAL SAFETY

■DO NOT operate or service this equipment before

reading this entire manual.

■This equipment should not be operated by persons

under 18 years of age.

■NEVER operate this equipment without proper

protective clothing that is flame-resistant (wool or
leather), welding shield, ventilator, steel-toed
boots and other protective devices required by
the job.

■NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or welder/AC generator.

■High Temperatures – Allow the engine to cool before adding

fuel or performing service and maintenance functions. Contact
with hot components can cause serious burns.

■The engine of this welder/AC generator requires an adequate

free flow of cooling air. Never operate the welder/AC generator
in any enclosed or narrow area where free flow of the air is

restricted. If the air flow is
restricted it will cause serious
damage to the welder/AC
generator engine and may

cause injury to people. The
engine gives off DEADLY
carbon monoxide gas.

■ 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 feeling

well due to fatigue, illness or taking medicine.

■NEVER operate this equipment under the

influence or drugs or alcohol.

■NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.

■Manufacture does not assume responsibility for any accident

due to equipment modifications.

■Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■Always check the machine for loosened threads or bolts before

starting.

■DO NOT weld near flammable liquids.

■Always refuel in a well-ventilated area, away from sparks and

open flames.

Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT
the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.

■NEVER operate the welder/AC generator in an explosive

atmosphere or near combustible materials. An explosion or
fire 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.

smoke around or near

PAGE 6 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

RULES FOR SAFE OPERATION

CAUTION:

This welder/AC generator is a source of
providing LETHAL high voltages. Never
permit unqualified personnel-especially

children to operate the welder/AC generator.

■This welder/AC generator is equipped with a ground terminal

for your protection. Always complete the grounding path from
the welder/AC generator to an external grounding source.

■NEVER operate this welder/AC generator, or handle any

electrical equipment while standing in water, while bare foot,

while hands are wet, or in the rain. Dangerous electrical
shock could occur causing severe bodily harm or even death.

■Arc rays can cause blindness. Always wear protective

shield when welding.

CAUTION:

CAUTION:

■Never use damaged or worn cables when connecting

power tools or equipment to the welder/AC generator.
Make sure power connecting cables are securely
connected to the generator’s output terminals. Insufficient
tightening of the terminal connections may cause damage
to the welder/AC generator and electrical shock.

CAUTION:

DO NOT touch or open coolant drain plug,

radiator cap, or engine oil drain plug while
the welder/AC generator is running.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.

■NEVER touch output terminals or electrode during

operation. This is extremely dangerous. Always stop the
machine when contact with the output terminals and
welding electrode.

CAUTION:

■Backfeed to a utility system can cause electrocution and/or

property damage. Do not connect to any building's electrical
system except through an approved device or after building
main switch is opened.

Emergencies

■ Always know the location of the nearest fire extinguisher

and 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 invaluable
in the case of an emergency.

Maintenance Safety

■ NEVER lubricate components or attempt service on a running

machine.

■ Always allow the machine a proper amount of time to cool

before 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 potentially

hazardous waste are used motor oil, fuel, coolant and fuel
filters.

■ DO NOT use plastic containers to dispose of hazardous

waste.

■ DO NOT pour waste, oil, coolant or fuel directly onto the

ground, down a drain or into any water source.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 7

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 and
maintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decals
become unreadable, replacements can be obtained from your dealer.

PAGE 8 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

OPERATION AND SAFETY DECALS

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 9

DAW-500S — SPECIFICATIONS

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The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient
conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric
reading 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

°°

°

Fahrenheit above the standard temperature of 60

°°

F.

F

PAGE 10 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — GENERAL INFORMATION

DAW-500S FAMILIARIZATION
Generator

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

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 event
of low oil pressure, high coolant temperature and failure of
the battery to charge. If any of the above conditions occur
while operating the welder/AC generator, it will cause a
complete unit shut down.

Battery Charge Indicator

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

Water Temperature Indicator

This unit is equipped with an apparatus that signals an
indicator and automatically stops the engine when the cooling
water temperature becomes abnormally high. This apparatus
will not function properly if the machine is operated with
less than the proper amount of coolant.

Oil Pressure Warning Indicator

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

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

Engine

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

In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.

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

Circuit Breakers

To protect the welder/AC generator from an overload,

pole, 25 amp, main circuit breaker is provided. In addition a
single 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 been
thoroughly inspected and accepted prior to shipment from
the factory. However, be sure to check for damaged parts or
components, or loose nuts and bolts, which could have
occurred in transit.

a single-

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 11

DAW-500S — DIMENSIONS

Dry Weight: 1,025 lbs.

Figure 1. DAW-500S Dimensions

PAGE 12 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

Total Weight: 1,150 lbs.

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 below
and 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 the

welder/AC generator into the open air. NEVER block this
opening.

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

4. Lifting Hook – Use this hook to lift the welder/AC
generator.

5. Engine Air Cleaner – Prevents dirt and other debris from
entering the fuel system. Lift locking latch on air filter
cannister to gain access to filter element.

6. Overflow Bottle – Supplies coolant to the radiator when
radiator coolant level is low. Fill to indicated level as shown
on bottle.

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

8. Coolant Drain Plug – Remove this plug to drain coolant
from the radiator.

9. Oil Drain Plug – Remove this plug to drain oil from the
engine.

10. Automatic Speed Control Solenoid – Automatically
regulates engine speed.

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

12. Battery – Provides +12 VDC power for the welder/AC
generator. When replacing battery (12V 35 AH) use only
recommended type battery.

13. G.F.C.I Ground Terminal – Use this terminal to connect
external equipment grounds so that the GFCI receptacle
will have a ground path.

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

Figure 2. Controls and Indicators

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 13

DAW-500S — CONTROLS AND INDICATORS

15. Fuel Drain Plug – Remove this plug to drain fuel from the

fuel tank.

16. Frame Ground Lug – Connect a ground strap between
this lug and a ground rod. Make sure the ground rod is
inserted deep into the ground to provide a good earth
ground. Consult with local Electrical and Safety Codes for
proper connection.

17. Oil Filter – Provides oil filtering for the engine.

18. Ignition Switch – With key inserted turn clockwise to start

engine.

19. Hour Meter – Indicates number of hours machine has
been in use or hours engine was run.

20. Circuit Protector Circuit Breaker – This single pole circuit
breaker provides circuit protection (120V @20 amps) for
the G.F.C.I. receptacle.

21. Receptacle G.F.C.I. – This receptacle provides 120 volts
output at 20 amps.

22. Receptacle – Provides 120 volts output at 25 amps.

23. Welding Output Terminals – Connect the welding cable

to this terminal. Select the appropriate polarities according
to the application. See Table 7.

24. Main Circuit Breaker – This single-pole circuit breaker
provides circuit protection (125V @25 amps) for the electric
parts assembly.

25. Current Control (CC) Voltage Control (CV) Adjustment
Knobs – Use these controls to adjust welding current and

voltage.

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.

27. Sub-Selector Switch-This switch is used to select type of

welding and welding voltage needed. This switch will not
work in CC mode.

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

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

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

31. Warning Lamp Display – Lights red when the following
conditions occur:

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

Figure 3. Controls and Indicators (con't)

PAGE 14 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — TRAILER-SAFETY GUIDELINES

CAUTION:

ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer ser­vice and maintenance information. The service and main­tenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents 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 for
the equipment in use. Fuel cells must be empty when
transporting equipment.

2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.

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 millimeters
(175,185,205, etc.). The tire diameter must match the
diameter 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 trailer’s
axle.

11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must 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 lug
nuts. See Table 4 and Figure 5 for lug nut tightening and
sequence.

13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3 on page 17). Please not that
some trailers have a double axle. This will be shown as
2-6000 lbs., meaning two axles with a total weight ca­pacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shock
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle. See page 16 for
proper wiring connections.

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

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

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

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

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

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 15

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

DAW-500S — TRAILER-SPECIFICATIONS

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DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

DAPTALF

PAGE 16 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — TRAILER-SPECIFICATIONS

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LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

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ELBATSUJDA2

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FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

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FX07-RLRT SSALCLLAB"2

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DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 17

DAW-500S — TRAILER TIRES & SUSPENSION

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing
the trailer wheels it is important the wheels, tires, and axle
are properly matched.

CAUTION:

DO NOT attempt to repair or modify a
wheel. DO NOT install an inner tube to
correct a leak through the rim. If the
rim is cracked, the air pressure in the

inner tube may cause pieces of the rim
to explode (break off) with great force and cause serious
eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in
preserving tire life. Pressure should be checked cold before
operation. DO NOT bleed air from tires when they are hot.
Check inflation pressure weekly to insure the maximum
tire life and to prevent premature tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.

Suspension

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

CAUTION:

NOTE

ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.

PAGE 18 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

Figure 4. Suspension Components

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TLOB-U"61/706-XAM54-NIM

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DAW-500S — TRAILER TIRES & SUSPENSION

stnemeriuqeReuqroTnoisnepsuS.4elbaT

SHACKLE BOLT
SPRING EYE BOLT

SHOULDER TYPE
SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY
LOCKING NUTS OR COTTER PINS ARE PROVIDE D T O

-

RETAIN NUT

BOLT ASSEMBLY

.

05-XAM03-NIM

.

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure 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. Tighten
each lug nut in 3 separate passes as defined by Table

5.

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

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"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09

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

ssaPdnoceS

SBL-TF

ssaPdrihT

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Figure 5. Lug Nut Tightening Sequence

NOTE

NEVER use an pneumatic air gun to
tighten wheel lug nuts.

DAW-500S — TRAILER WIRING DIAGRAMS

NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 20 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — INSTALLATION

Outdoor Installation

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

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

Foreign materials such as dust, sand, lint and abrasive
materials will cause excessive wear to engine and alternator
parts.

CAUTION :

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet away from any wall. Using an exhaust pipe
which is too long or too small can cause excessive back
pressure and cause the engine to heat excessively.

Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any diesel engine are
very poisonous if discharged in a closed room, but harmless
if allowed to mix with the outside air. If the welder/AC
generator is installed indoors, you must make provisions for
venting the engine exhaust to the outside of the building.

Pay close attention to ventilation when
operating the welder/AC generator inside
tunnels and caves. The engine exhaust
contains noxious elements.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 21

DAW-500S — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the welder/AC generator
is level. With the dipstick inserted all the way, but without
being screw into the filler hole, verify that the oil level is
maintained between the two notches (Figure 6) on the
dipstick. Use grade CC or higher when refilling. See Table 6
for proper selection of engine oil.

Fuel

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

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

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

CAUTION :

Never fill the fuel tank while the engine is
running or in the dark. Fuel spillage on a
hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled
gasoline completely to prevent fire
hazards.

Coolant

Figure 6. Engine Oil Dipstick

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Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.

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

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)°51-(C°5woleB03-W01EASroW01EAS

PAGE 22 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — PRE-SETUP

CAUTION :

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

Day-to-day addition of coolant or
antifreeze is done from the reserve tank. See Table 7 for
engine, radiator and reserve tank coolant capacities. Make
sure the coolant level in the reserve tank is always between
the "H" and the "L" markings.

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Day-to-day addition of coolant is done from the

Operation in Freezing Weather

When operating in freezing weather, be certain that the proper
amount of antifreeze has been added. See Table 8 for
antifreeze operating temperatures.

Cleaning the Radiator

The radiator may overheat if the fins become overloaded
with dust or debris. Periodically clean the radiator fins with
compressed air. Change the radiator fluid every two yearsl

Fan Belt Tension

The deflection of the fan belt may contribute to overheating,
or to insufficient charging of the battery. Inspect and adjust
it in accordance with the Kubota Engine Operator's
Manual.

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

Figure 7. Fan Belt Tension

CAUTION :

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NOTE

When the antifreeze is mixed with
water, the antifreeze mixing ratio must
be less than 50%.

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

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Kubota Engine Operator's Manual.

Battery

Connect the battery to correct polarity. DO NOT connect in
reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.

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

Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions, always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 23

DAW-500S — INSTRUMENTATION

CAUTION :

When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the welder/AC
generator set.

Power Outlets

The welder/AC generator has the following single-phase 60
Hz, 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/AC
generator from short circuiting or overloading from the 60
Hz single-phase load.

GFCI Protection Breaker (Single-Pole)

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

Idle Control Switch

The DAW-500S Welder/AC generator is provided with an
automatic idle (engine) control capability for noise
suppression and fuel cost reduction. The automatic idle
control feature automatically engages under a no-load
condition.

When the Idle Control Switch is placed in the “ON” position,
the engine revolutions will be approximately 2000 rpm (low­speed operation). When a load is connected to one of the
output receptacles, the engine speed will automatically
increase to about 2800 rpm (high-speed operation) within 10
seconds. Conversely, when the load is removed, the engine
speed will automatically drop back down to 2000 rpm within
10 seconds.

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

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

However, when welding in CV Low, the engine will continue
to 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 before
connecting the load, to confirm that the receptacle is
functioning correctly.

PAGE 24 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the welder/AC
generator and equipment to insure the wattage, amperage
and frequency requirements are satisfactorily supplied by
the welder/AC generator for operating the equipment.

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.

NOTE

If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

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

CAUTION:

Motors and motor-driven equipment draw
much greater current for starting than
during operation.

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

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

CAUTION:

Before connecting this welder/AC
generator to any building’s electrical
system, a licensed electrician must install
an isolation (transfer) switch. Serious injury
or death may result without this transfer
switch.

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! When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.

! When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s 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 current
capacity.

When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 25

DAW-500S— WELDER OPERATING INSTRUCTIONS

Welding Cables and Polarities

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

Figure 8. Electrode Cable Connection

(Correct)

NOTE

ALWAYS attach terminal connectors at

the end of each cable. NEVER connect
exposed or frayed wires (Figure 9)
directly to the terminals. Exposed wiring
may cause shocks or di-electric
breakdown from poor contact.

Figure 9. Electrode Cable Connection

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PAGE 26 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S— WELDER OPERATING INSTRUCTIONS

CAUTION :

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

CV MODE

This mode is for use of wire feeders. Use the voltage control
to adjust the feeding speed. See Table 11 for maximum
voltage range in relevant to electrode size.

CV HIGH

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

NOTE

The CC Current Regulator will not function in this
position.

CC Mode (for stick)

This mode is for use of welding sticks. Use the current
regulator to adjust the feeding speed. See Table 11 for
maximum current range in relevant to electrode size.

CC HIGH

Adjust the CC Current Regulator for welding current, with
Main Welding DV/CC Selector Switch turned to the right side
and the Sub Welding CV/CC Selector Switch turned to the
lower position .

NOTE

The CV Voltage Regulator will not function in this
position.

CC LOW

Adjust the CC Current Regulator for welding current, with
Main Welding CV/CC Selector Switch turned to the left side.

CV LOW Position

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

NOTE:

The idle control switch will not function and the engine
will remain on low speed during welding operation in
this mode.

egnaRtnerruC

NOTE

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

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DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 27

DAW-500S — WELDER/GENERATOR USE

Ground

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

Connect the terminal of the ground wire between the lock
washer and the nut and tighten the nut fully. Connect their
end of the wire to a suitable ground.

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0031#0/1#0/2#0/3#0/4#0/2-2#0/2-2#
0530/1#0/2#0/3#0/4#0/2-2#0/3-2#0/3-2#

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Welding Cable

When welding, use the table below (Table 12) to measure
the optimum amount of voltage and amperes when selecting
the proper welding cable. The relationship between cable
length and sectional area is to keep the line voltage drop
within 4V.

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0050/3#0/4#0/2-2#0/3-2#0/4-2#0/3-3#0/3-3#

Welding and Auxiliary Outputs

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

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

Welding/AC Power

This unit will provide simultaneous use of DC welding power
and AC output power. Use the table below (Table 13) when
selecting electrode size for the amount of AC power
available.

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PAGE 28 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)

DAW-500S— WELDER/GENERATOR USE

Duty Cycle

The welder is rated at 100% duty cycle at 350 amps. Duty
Cycle refers to the amount of time the user can weld and
how long the machine must rest. The duty cycle depends
upon the welding current being used. Select the appropriate
duty cycle from Table 14 to prevent overload.

EXAMPLE:

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

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FIVE ESSENTIALS FOR PROPER
WELDING PROCEDURES

Besides the steady sizzling sound that a correct arc
produces, the shape of the molten pool and the move­ment of the metal at the rear of the pool serve as a guide
in checking weld quality. In a correctly made deposit, the
ripples produced on the bead will be uniform and the bead
will be smooth, with no overlap or undercut.

1. Correct Electrode Size

The correct choice of electrode size involves consider­ation of a variety of factors. Such as the type, position,
and preparation of the joint, the ability of the electrode to
carry high current values without injury to the weld metal
or loss of deposition efficiency. The mass of work metal
and its ability to maintain its original properties after
welding, the characteristics of the assembly with refer­ence to effect of stresses set up by heat application, the
practicability of heat treatment before and/or after welding,
the specific requirements as to welding quality and the
cost of achieving the desired results.

2. Correct Current

If current on equipment is too high or too low, you are
certain to be disappointed in your weld. If too high, the
electrode melts too fast and your molten pool is large and
irregular. If too low, there is not enough heat to melt the
base metal and your molten pool will be too small, will pile
up, and look irregular.

3. Correct Arc Length

If the arc is too long or voltage too high the metal melts
off the electrode in large globules which wobble from side
to side as the arc wavers, giving a wide, spattered and
irregular bead–with poor fusion between original metal and
deposited metal.

If the arc is too short or voltage too low, there is not
enough heat to melt the base metal properly and the
electrode quite often sticks to the work. This gives a high,
uneven bead, having irregular ripples and poor fusion.

4. Correct Travel Speed

When your speed is too fast: your pool does not last long
enough, impurities and gas is locked in. The bead is
narrow and ripples pointed. When speed is too slow: the
metal piles up, the bead is high and wide, with a rather
straight ripple.

5. Correct Electrode Angle

The electrode angle is of particular importance in fillet
welding and deep groove welding. Generally speaking,
when making a filet weld, the electrode should be held so
that it bisects the angle between the plates and is
perpendicular to the line of weld. If under cut occurs in the
vertical member lowers the angle of the arc and directs
the arc toward the vertical member.

CAUTION :

Always wear welding shield with correct
filter shade when welding. Improper use,
or looking directly at the arc will lead to
blindness.

CAUTION :

Use protective screens or barriers to
protect others from flash and glare; warn
others not to stare at the welding arc.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01) — PAGE 29

DAW-500S — ENGINE OPERATING INSTRUCTIONS

WARNING:

The engine's exhaust contains harmful
emissions. ALWAYS ventilate the
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.

Before Starting

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

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

CAUTION:

If any diesel spillage occurs, completely
wipe up the spilled diesel fuel.

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

Starting

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

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

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

3. Insert the key into the starter switch and turn it to the “RUN”
position. Check to see the oil pressure and charge lights
on the "Warning Lamp Unit " are lit. If either are not lit, check
the system and wiring (refer to the Kubota Engine
Operator's Manual).

4. Turn the key to the 'HEAT' position. When the preheat light
is 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.

4. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure the radiator cap is
fastened securely.

Figure 11. Key switch set to 'HEAT'

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

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

CAUTION:

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

PAGE 30 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01)