MQ Power WHISPERWELD DAW-500S User manual

© COPYRIGHT 2001, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
MQPOWER
WHISPERWELDTM
WELDER/A.C.GENERATOR
Model DAW-500S
Revision #0 (07/19/01)
MULTIQUIPINC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-4 7-1 44
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700 SERVICE DEPARTMENT:
800-4 1-1 44 800-835- 551
FAX: [phone] FAX: [phone]
E-mail:[email protected] •www:multiquip.com
PART No. D6845 00104B

PAGE 2 —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 HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/ 37-3700
FAX: [phone] or 310/637-3284
SERVICE DEPARTMENT
800/83 -2 1 or 310/ 37-3700
FAX: [phone]
WARRANTY DEPARTMENT
800/83 -2 1 or 310/ 37-3700
FAX: [phone]
MAIN
800/421-1244 or 310/ 37-3700
FAX: [phone]

PAGE 4 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
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 ............................................................. 1
Controls and Indicators ...................................... 13-14
Trailer Safety Guidelines ......................................... 15
Trailer Specifications .......................................... 16-17
Trailer Tires and Suspension ............................. 18-19
Trailer Wiring Diagram............................................. 0
Installation ............................................................... 1
Pre-Setup ........................................................... - 3
Instrumentation ....................................................... 4
Load Application ..................................................... 5
Welder Operating Instructions ........................... 6- 7
Welder/Generator Use ....................................... 8- 9
Engine Operating Instructions ........................... 30-31
Maintenance ...................................................... 3 -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/ACGenerator
Generator Assembly .......................................... 4 -43
Control Panel Assembly ..................................... 44-45
Electric Parts Assembly...................................... 46-47
Engine and Radiator Assembly.......................... 48-49
Battery Assembly ............................................... 50-51
Muffler Assembly ............................................... 5 -53
Fuel Tank Assembly ........................................... 54-55
Enclosure Assembly........................................... 56-57
Enclosure (Rubber Seals) .................................. 58-59
Name Plate and Decals ..................................... 60-61
Crankcase Assembly ........................................... 6 -63
Oil Pan Assembly ................................................. 64-65
Cylinder Head Assembly ...................................... 66-67
Gear Case Assembly ...........................................68-69
Head Cover Assembly ......................................... 70-71
Oil Filter Assembly ............................................... 7 -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 ........................... 8 -83
Flywheel Assembly .............................................. 84-85
Fuel Camshaft Assembly .....................................86-87
Engine Stop Lever Assembly ...............................88-89
Stop Solenoid Assembly ...................................... 90-91
Injection Pump Assembly ..................................... 9 -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 ............10 -103
Fuel Filter Assembly ........................................104-105
Fuel Pump Assembly .......................................106-107
Alternator Assembly ......................................... 108-109
Alternator Component Assembly .....................110-111
Starter Assembly ............................................. 11 -113
Starter Component Assembly..........................114-115
Oil Switch Assembly ......................................... 116-117
Water Flange and Thermostat Assembly.........118-119
Water Pump Assembly .....................................1 0-1 1
Fan Assembly...................................................1 -1 3
Valve and Rocker Arm Assembly ..................... 1 4-1 5
Inlet Manifold Assembly ...................................1 6-1 7
Exhaust Manifold Assembly .............................1 8-1 9
Air Cleaner Assembly....................................... 130-131
Hydraulic Pump Assembly ............................... 13 -133
Glow Plug Assembly ........................................134-135
Starter Switch Assembly ..................................136-137
Accessories ......................................................138-139
Terms and Conditions Of Sale — Parts .................. 140
NOTE
Specification and part
number are subject to
c ange wit out notice.
KUBOTAD1703-EB ENGINE

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 5
PARTS ORDERING PROCEDURES
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.
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
Earn Extra Discounts when
you order by FAX!
All parts orders hich include complete part numbers
and are received by fax qualify for the follo ing extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nation ide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
■■
■■
■Dealer account number
■■
■■
■Dealer name and address
■■
■■
■S ipping address (if different t an billing address)
■■
■■
■Return fax number
■■
■■
■Applicable model number
■■
■■
■Quantity, part number and description of eac part
■■
■■
■Specify preferred met od of s ipment:
•UPS Ground
•UPS Second Day or Third Day*
•UPS Next Day*
•Federal Express Priority One (please provide us ith 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 Discount
for Domestic USA
Dealers Only

PAGE 6 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
RULES FOR SAFE OPERATION
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.
■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.
■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 smoke around or near
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.
■NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or welder/AC generator.
■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.
■High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact
with hot components can cause serious burns.
CAUTION:
■DO NOT weld near flammable liquids.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 7
■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, w ile bare foot,
w ile ands are wet, or in t e rain. Dangerous electrical
shock could occur causing severe bodily harm or even death.
■Arc rays can cause blindness. Always wear protective
shield when welding.
RULES FOR SAFE OPERATION
This welder/AC generator is a source of
providing LETHAL high voltages. Never
permit unqualified personnel-especially
children to operate the welder/AC generator.
Emergencies
■ Always know the location of the nearest fire extinguis er
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.
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.
■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.
CAUTION:
CAUTION:
■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:

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

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

PAGE 10 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
DAW-500S — SPECIFICATIONS
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 9.9 inches and a temperature of 60 degrees Fahrenheit.
Generally, the engine output power will decrease 3 1/ % for each 1000 feet of altitude above sea level, and 1% for each 10°°
°°
° F
Fahrenheit above the standard temperature of 60°°
°°
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DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 11
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 1 0 volt receptacle, 0 amp (single-phase)
!One 1 0 volt receptacle, 30 amp (single-phase)
!Main Circuit Breaker 1 5V @ 5 Amps
!Circuit Protector Breaker (GFCI) 1 0V @ 0 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 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, a single-
pole, 5 amp, main circuit breaker is provided. In addition a
single pole, 0 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.

PAGE 12 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
Figure 1. DAW-500S Dimensions
DAW-500S — DIMENSIONS
Dry Weight: 1,0 5 lbs.
Total Weight: 1,150 lbs.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 13
Figure 2. Controls and Indicators
DAW-500S — CONTROLS AND INDICATORS
Figures 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 #
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 +1 VDC power for the welder/AC
generator. When replacing battery (1 V 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 ( 5 liters) of diesel fuel.

PAGE 14 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
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 (1 0V @ 0 amps) for
the G.F.C.I. receptacle.
21. Receptacle G.F.C.I. – This receptacle provides 1 0 volts
output at 0 amps.
22. Receptacle – Provides 1 0 volts output at 5 amps.
23. Welding Output Terminals – Connect the welding cable
to this terminal. Select the appropriate polarities according
to 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 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:
Figure 3. Controls and Indicators (con't)
24. Main Circuit Breaker – This single-pole circuit breaker
provides circuit protection (1 5V @ 5 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.

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 15
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 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 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 .
1. Fuel Cell - Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding 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 — 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.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,1 ,14, etc.), and the width in millimeters
(175,185, 05, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
-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.
1 . 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
-6000 lbs., meaning two axles with a total weight ca-
pacity 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.
Specifications may change without notice. Contact MQ
Power Sales for information of specific trailer to unit.

PAGE 16 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
DAW-500S — TRAILER-SPECIFICATIONS
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FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005 DAPTALF
FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005 DAPTALF
XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005 DAPTALF

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 17
DAW-500S — TRAILER-SPECIFICATIONS
)t'noC(snoitacificepS.2elbaT
LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE
W51-01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4 TALFELOP4
X01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
FX01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
W522-RLRT SSALCLLAB"2 ELBATSUJDA2 B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4
004WLB SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4
FX51-RLRT SSALCLLAB"2CRL31-87B"05.4X"31"2/1-2#0053GUL5FAEL4REBBURELOP4 TALF
X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053 "8/3-2 GUL5FAEL4REBBURELOP4 TALF
FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053 "8/3-2 GUL5FAEL4REBBURELOP4 TALF
W07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41.sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
X07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
FX07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41.sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
FX001-RLRT 6/5-2ELBATSUJDA EYE"3TPO C51-502 )4(SAIB "5.5X"41sbl0053 "3 GUL5FAEL5MOOLERIW4
521/58-RLRT 6/5-2ELBATSUJDA EYE"3TPO D51R57/522TS )4(LAIDAR "6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4
FX051-RLRT EYELLAB"3E61-057 )4(SAIB "7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4
FX022-RLRT EYE"3 ELBATSUJDA E61R58/532TS )4(LAIDAR "7X"61sbl0007-)2(GUL8XELFQMOOLERIW4
FX003-RLRT EYE"3 ELBATSUJDA E61R58/532TS )6(LAIDAR "7X"61sbl0006-)2(GUL8XELFQMOOLERIW4
FX004-RLRT EYE"3 ELBATSUJDA E61R58/532TS )6(LAIDAR "7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4
FX006-RLRT LEEHWHT5H5.71R57/512TS )8(LAIDAR "7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6
RA008-RLRT LEEHWHT5H5.71R57/512TS )8(LAIDAR "7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6

PAGE 18 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
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 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
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.
DAW-500S — TRAILER TIRES & SUSPENSION
Figure 4. Suspension Components

DAW-500S WELDER/A.C. GENERATOR — PARTS & OPERATION MANUAL — REV.#0 (07/19/01 — PAGE 19
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.
. 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.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DAW-500S — TRAILER TIRES & SUSPENSION
Figure 5. Lug Nut Tig tening Sequence
stnemeriuqeReuqroTeriT.5elbaT
eziSleehWssaPtsriF SBL-TF ssaPdnoceS SBL-TF ssaPdrihT SBL-TF
"2152-0204-5356-05
"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
stnemeriuqeReuqroTnoisnepsuS.4elbaT
metI ).sbL-.tF(euqroT
TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG FIT ONLY.PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
SHOULDER TYPE
SHACKLE BOLT 05-XAM03-NIM

PAGE 20 —DAW-500S WELDER/A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #0 (07/19/01
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
DAW-500S — TRAILER WIRING DIAGRAMS