TM-4412 March 2002
Eff. w/Serial Number LC1 10463
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. AC Auxiliary Power Curve 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Manufacturer’s Rating Label 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator (See Section 4-3) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Exhaust Pipe 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mounting Welding Generator 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting The Battery 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Engine Prestart Checks 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Adding C o o l a n t To Radiator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting To Remote 14 Receptacle RC14 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATING WELDING GENERATOR 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Control Switch 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Voltage/Amperage Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIAR Y EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. 120 Volt And 240 Volt Receptacles 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Maintenance Label 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Inspecting/Cleaning Optional Spark Arrestor 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Servicing Fuel And Lubrication Systems 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Servicing Engine Cooling System 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – THEORY OF OPERATION 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – EXPLANATION OF ELECTRICAL PARTS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – TROUBLESHOOTING 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) 40. . . . . . .
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) 42. . . . . . . . . . . . . . . . . .
10-4. Waveforms For Section 10-2 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Filter Board PC6 Testing Information 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Filter Board PC6 Test Point Values 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9 46. . . . . . . . . . . . . . . . . . . .
10-8. Using Diagnostic LED’s On LED Board PC9 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. LED Board PC9 Testing 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10.Diagnostic LED’s On LED Board PC9 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11.Replacing Brushes And Cleaning Slip Rings 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12.Checking Unit Output After Servicing 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the Sate of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause cancer,
birth defects, and other
reproductive harm.
(Continued)
TABLE OF CONTENTS
SECTION 11 – DISASSEMBLY AND REASSEMBLY 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Disassembly Of Generator 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 – ELECTRICAL DIAGRAMS 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 – RUN-IN PROCEDURE 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 – PARTS LIST 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_rtm 7/99 / OM-4412
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should test, maintain, and repair this
unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un-
less the procedure specifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ENGINE EXHAUST GASES can kill.
D Do not breathe exhaust fumes.
D Use in open, well-ventilated areas, or vent ex-
haust outside and away from any building air intakes.
FUEL can cause fire or explosion.
D Stop engine and let it cool of f before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
D Keep away from moving parts such as
fans, belts, and rotors.
D Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from mov-
ing parts.
D Before working on generator, remove spark plugs or injec-
tors to keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on gener-
ator components.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connect-
ing battery cables.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and –) on batteries.
D Disconnect negative (–) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
TM-4412 Page 1D502K 5+4
STEAM AND HO T C OOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
FALLING UNIT can cause injury.
D Use equipment of adequate capacity to lift and
support unit and components.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Securely attach components to lifting equip-
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
TILTING OR TIPPING can cause injury.
D Do not put any body part under unit while lifting.
D Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
D Be careful when working on stator and rotor assemblies.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OVERUSE can cause OVERHEATING.
HOT PARTS can cause severe burns.
D Allow cooling period before servicing.
D Wear protective gloves and clothing when
working on a hot engine.
D Do not touch hot engine parts bare-handed.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
TM-4412 Page 2
D502K 5+4
SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
A
Stop Engine
Starting Aid Battery (Engine)
Check Injectors/
Pump
Positive Negative
Amperes
Fast (Run, Weld/
Power)
Check Valve
Clearance
Volts Panel/Local Remote
V
Air Temperature Or
Engine
Stick (SMAW)
Welding
Engine
Temperature
Constant Current
(CC)
Slow (Idle) Start Engine
Engine Oil
Pressure
Fuel
Certified/Trained
Mechanic
Output
MIG (GMAW)
Welding
Engine Oil
Protective Earth
(Ground)
Welding Arc
Alternating
Current
TIG (GTAW)
3
Time
Three Phase
Electrode
Connection
Contactor On
h
Hours
Read Operator’s
Manual
Work Connection
s
G
Seconds
Circuit Breaker
Engine-Driven,
Three-Phase
Alternator With
Rectifier
1
Hz
Single Phase
Do Not Switch
While Welding
Hertz
D502K 5+4
TM-4412 Page 3
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
CV/DC
Weld
Output
Range
20 – 600 A
14 – 40 V
Rated Welding
Output
500 A, 40 Volts DC,
100% Duty Cycle
100% Duty Cycle
600 A, 44 Volts DC,
40% Duty Cycle
Maximum
Open-Circuit
Voltage
95
56
Auxiliary Power Rating Engine
4 kVA/kW, 20/17 A,
120/240 V AC, 50/60 Hz
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
Width
Depth 69-1/2 i n (1765 mm)
A 69-1/2 i n (1765 mm)
B* 55-7/8 i n (1419 mm)
C* 46-3/8 i n ( 1178)
D* 9-1/2 in (241 mm)
E 27-1/2 in (699 mm)
F 1 in (25 mm)
G 29-1/2 i n (749 mm)
H
* With mounting brackets in center
position. Dimensions vary with location of mounting brackets.
No fuel: 1808 lb (820 kg)
50 in (1270 mm)
(to top of muffler)
28-1/2 i n (724 mm)
(mtg. brackets turned in)
30-3/4 in (781 mm)
(mtg. brackets turned out)
9/16 in (14 mm) Dia.
4 Holes
Weight
A
B
C
D
G
H
Front Panel End
E
Standard:
Single-Phase,
Single-Phase,
F
802 161-A
802 161-A
Fuel
Capacity
Kubota V3300-B
Water-Cooled, Four
Water-Cooled, Four
Cylinder, 49 HP Diesel
Engine
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
Y Do not move or operate unit where it could
tip.
tip.
20°
20
20°
25 gal
25 gal
(95 L)
30°
30°
803 122
TM-4412 Page 4 D502K 5+4
3-3. Volt-Ampere Curves
A. Stick Mode
100
80
60
40
DC VOLTS
20
0
0 100 200 300 400 500 600 700 800 900 1000
B. MIG Mode
100
80
DC AMPERES
Ranges
300 – Max
185 – 525
125 – 400
85 – 250
55 – 125
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of al l
other settings fall between the
curves shown.
60
40
DC VOLTS
20
0
0 100 200 300 400 500 600 700 800 900 1000
C. TIG Mode
100
80
60
40
DC VOLTS
MAX
MIN
DC AMPERES
Ranges
60–450
40–330
30–220
20–110
20
0
0 100 200 300 400 500 600 700
D502K 5+4
DC AMPERES
208 135 / 203 415 / 208 136
TM-4412 Page 5
3-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
LITERS/HR.
11.35
10.40
9.46
8.51
7.57
6.62
5.67
4.73
3.78
2.84
1.98
0.95
0.00
US GAL./HR.
3.00
2.75
2.50
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
0 100 200 300 400 500 600 700
DC WELD AMPERES AT 100% DUTY CYCLE
208 137
3-5. Duty Cycle And Overheating
100% Duty Cycle At 500 Amperes
Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
TM-4412 Page 6 D502K 5+4
202 356
3-6. AC Auxiliary Power Curve
300
150
250
125
200
100
150
75
AC VOLTS
100
50
50
25
0
0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0102030405060
AC AMPERES IN 120V MODE
The ac power curve shows the auxiliary power in amperes available at
the 120 and 240 volt receptacles.
3-7. Manufacturer’s Rating Label
193 018
D502K 5+4
TM-4412 Page 7
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator (See Section 4-3)
Movement Airflow Clearance Location
18 in
OR
18 in
(460 mm)
18 in
(460 mm)
(460 mm)
(460 mm)
18 in
(460 mm)
18 in
OR
Grounding
1
Electrically bond generator frame to
vehicle frame by metal-to-metal
2
contact.
4-2. Installing Exhaust Pipe
OR
GND/PE
Y Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
3
4
2
install2 1/01– Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
with all DOT and other applicable codes.
Y Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding Terminal
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
Y If unit does not have GFCI re-
ceptacles, use GFCI-protected extension cord.
Y Stop engine and let cool.
. Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
TM-4412 Page 8 D502K 5+4
803 122 / Ref. 802 169 / Ref. 202 705
4-3. Mounting Welding Generator
1
Welding Unit In Place
Bolting Unit In Place
1
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
1 Mounting Bracket
2 1/2 in Bolt And Washer
(Minimum – Not Supplied)
3 3/8-16 x 1 in Screws
(Supplied)
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
To Bolt Unit In Place:
2
Remove hardware securing the
four mounting brackets t o the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Tools Needed:
9/16 in
4-4. Connecting The Battery
Y Connect Negative (–) Cable Last.
+
3
803 122 / Ref. 802 169-B
. Reinstall cover after connecting battery.
–
Tools Needed:
1/2 in
D502K 5+4
802 168-E / Ref. 202 705 / 802 313 / S-0756-C
TM-4412 Page 9
4-5. Engine Prestart Checks
Diesel
Full
Remove air bleed screw
when filling radiator.
See Section 4-6.
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Capacity: w/Overflow
Tank 10 qt (9.5 L)
Full
Coolant Recovery
Tank
Full
803 123-A
. Check all engine fluids daily .
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil. The
Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high.
. This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.
Fuel
Y Do not use gasoline. Gasoline will
damage engine.
Y Do not use ether to start engine.
Add fresh diesel fuel before starting to prevent air from entering the fuel system (see
engine maintenance label for fuel specifica-
TM-4412 Page 10 D502K 5+4
tions). Leave filler neck empty to allow room
for expansion.
Do not run out of fuel or air may enter fuel
system and cause starting problems. See
engine manual to bleed air from fuel system.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Y Engine may use oil and wetstacking
may occur during run-in. Check oil
several times daily during run-in.
Coolant
Check coolant level in radiator before starting unit the first time. Add coolant if below
bottom o f filler neck (see Section 4-6 for radiator filling instructions).
Check coolant level in recovery tank daily.
If coolant is below Cold Full level, add coolant until level in tank is between Cold Full
and Hot Full levels. If recovery tank coolant
level was low, check coolant level in radiator
(see Section 4-6).
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in thi s e n g i n e . D o n o t u s e 1 0 0 % a n t i freeze or severe damage will occur.
Keep radiator and air intake clean.
Y Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
. T o improve cold weather starting:
Use Engine Start/Preheat switch to operate glow plug (see Section 5-1).
Keep battery in good condition. Store
battery in warm area off concrete surface.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 7-1).
4-6. Adding Coolant To Radiator
1
Y Stop engine and let cool.
. Check coolant level according
to Section 4-5 before starting
this procedure.
Engine coolant is a mixture of water
and ethylene glycol base antifreeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. D o not use 100% antifreeze
or severe damage will occur.
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
1 Radiator Air Bleed Screw
2 Radiator Cap
Remove air bleed screw. Add cool-
ant to radiator until coolant is at bottom of filler neck. This ensures all
air is purged from the system.
Reinstall air bleed screw and radiator cap. Check coolant level in recovery tank (see Sect i o n 4 - 5 ) .
2
Tools Needed:
3/8 in
Full
Capacity: w/Overflow
Tank 10 qt (9.5 L)
D502K 5+4
803 123-A / 206 580
TM-4412 Page 11
4-7. Connecting To Weld Output Terminals
Tools Needed:
3/4 in
1
2
803 122
Y Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (–) Weld Output Terminal
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect electrode h o l der cable to Positive (+) terminal on
left and work cable to Negative (–) terminal
on right.
For Direct Current Electrode Negative
TM-4412 Page 12 D502K 5+4
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect electrode holder cable to Electrode
terminal on left and work cable to Work terminal on right.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive
(+) terminal on left and work cable to Nega-
tive (–) terminal on right. Use Process/Contactor Control switch to select type of weld
output (see Section 5-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right.
4-8. Selecting Weld Cable Sizes*
100 ft (30 m) or Less
Weld Output
Terminals
Y Stop engine before
connecting t o weld output terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Welding
Amperes
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
10 – 60%
Duty
Cycle
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
60 – 100%
Duty
10 – 100% Duty Cycle
Cycle
400 ft
(120 m)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
500 2/0 (70) 3/0 (95) 4/0 (120)
600 3/0 (95) 4/0 (120)
700 4/0 (120)
* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative.
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
D502K 5+4
TM-4412 Page 13
4-9. Connecting To Remote 14 Receptacle RC14
OUTPUT
24 VOLTS AC
24 VOLTS AC
Socket* Socket Information
A 24 volts ac. Protected by circuit
breaker CB5.
B Contact closure to A completes
24 volt ac contactor control
circuit.
C Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
*The remaining sockets are not used.
OR
803 122
REMOTE
D Remote control circuit common.
OUTPUT
CONTROL
115 VOLTS AC
GND
NEUTRAL G Circuit common for 24 and 115
E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
I
CB13.
Contact closure to I completes
115 volt ac contactor control
J
circuit.
K Chassis common.
volt ac circuit.
TM-4412 Page 14 D502K 5+4
Notes
D502K 5+4
TM-4412 Page 15
SECTION 5 – OPERATING WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
81213956
4
3
710
11
2
1
TM-4412 Page 16 D502K 5+4
206 212-A / 803 122
5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls
1 Start/Preheat Switch
Use switch to start engine and operate glow
plug for cold weather starting.
Engine runs at weld/power speed
continuously.
Turn switch to Preheat position to operate the
glow plug and heat the combustion chambers
before cranking engine (see starting instructions following).
2 Engine Shutdown Switch
Push switch down to stop engine.
To Start:
. If engine does not start, let engine come to
a complete stop before attempting restart.
Above 41 F (5 C): turn Start/Preheat switch
to Preheat position for 5 seconds and then turn
switch to Start position. Release Start/Preheat
switch when engine starts.
Below 41 F (5 C):
Turn Start/Preheat switch to Preheat position
for 15 seconds and then turn switch to Start.
Release Start/Preheat switch when engine
starts.
To Stop:
Push Engine Shutdown switch down to stop
engine.
3 Engine Hour Meter
Use meter to monitor engine running time for
scheduling maintenance.
Engine Gauges
. To read gauges with engine off, turn Start/
Preheat switch to Preheat position.
4 Fuel Gauge
Use gauge to check fuel level when engine is
running.
5 Battery Ammeter
Use gauge to check amperage output to the
battery. The gauge reads near 0 (zero) when
the engine is running. If gauge is at a negative
number, the battery is discharging.
Y Stop engine, and do not run engine un-
til problem is fixed.
6 Engine Temperature Gauge
Normal temperature is 170 - 205° F (77 - 96°
C). Engine stops if temperature exceeds 221°
F (105° C).
Weld Controls
7 Process/Contactor Control Switch
See Section 5-3 for Process/Contactor Con-
trol switch information.
8 Amperage Range Switch
Y Do not switch under load.
Use switch to select weld amperage range.
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
For most welding applications, use lowest amperage range possible to help prevent arc outages.
9 V oltage/Amperage Adjust Control
With Process/Contactor Control switch in any
Stick or TIG setting, use control to adjust am-
perage within range selected by Amperage
Range switch. With Process/Contactor Control switch in any MIG position, use control to
adjust voltage. With Voltage/Amperage Adjust
Control switch (item 10) in Remote position,
control limits the remote amperage in TIG
mode, but has no effect in Stick and MIG
modes.
Weld output would be about 263 A DC with
controls set as shown (50% of 125 to 400 A).
. The numbers around the control are for
reference only and do not represent an actual percentage value.
10 Voltage/Amperage Adjust Control Switch
And Remote 14 Receptacle
Use switch to select front panel or remote voltage/amperage control. For remote control,
place switch in Remote position and connect
remote control to Remote 14 receptacle RC14
(see Sections 4-9 and 5-4).
11 Polarity/AC Selector Switch (Optional)
Y Do not switch under load.
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
12 DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
13 DC Ammeter (Optional)
Ammeter displays amperage output of the unit.
D502K 5+4
TM-4412 Page 17
5-3. Process/Contactor Control Switch
1
1 Process/Contactor Control Switch
(See Section 5-1 For Location)
Y Weld output terminals are energized
when Process/Contactor Control
switch is i n a Weld Terminals Always
On position and the engine is
running.
Use switch to select weld process and weld
output on/off control (see table below and
Section 5-4).
Place switch in Weld Terminals Remotely
Controlled positions to turn weld output on
and off with a device connected to the remote 14 receptacle.
Place switch in Weld Terminals Always On
positions for weld output to be on whenever
the engine is running.
Use Weld T erminals Always On – CC Stick
position for air carbon arc (CAC-A) cutting
and gouging.
When switch is in a Weld Terminals Always
On – CC Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
The arc drive (dig) circuit is disabled when
switch is in MIG, TIG, and CC stick (With
Remote On/Off Control) positions.
Process/Contactor Control Switch Settings
Switch Setting Process Output On/Off Control
Weld Terminals Remotely Controlled – CC TIG
Weld Terminals Remotely Controlled – CC Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle
Weld Terminals Remotely Controlled – CV MIG MIG (GMAW) At Remote 14 Receptacle
Weld Terminals Always On – CV MIG MIG (GMAW) Electrode Hot
Weld Terminals Always On – CC Stick
GTA W With HF Unit, Pulsing Device,
Or Remote Control
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
At Remote 14 Receptacle
Electrode Hot
206 212-A
Weld Terminals Always On – CC Scratch Start TIG Scratch Start TIG (GTAW) Electrode Hot
TM-4412 Page 18 D502K 5+4
5-4. Remote Voltage/Amperage Control
1
1 Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 4-9).
Example: Combination Remote Amperage Control (Stick) With Remote On/Off Control
Set V/A
Adjust Switch
Example: Combination Remote Amperage Control (TIG) With Remote On/Off Control
Set Remote
Process
Set Range Control Not
Used In Remote
Stick Mode
Process = Stick (Using Remote On/Off)
In Example:
Range = 125 to 400 A DC
Min = 125 A DC
Max = 400 A DC
Max (400 A DC)
Min (125 A DC)
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 40 to 330 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 185 A DC (50% of 40 to 300)
Set V/A
Adjust Switch
D502K 5+4
Set Remote
Process
Set Range Set Control
Max (185 A DC)
Min (40 A DC)
Adjust Optional Remote Control
0774 / Ref. 192 895-A / 802 311-A
TM-4412 Page 19
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. 120 Volt And 240 Volt Receptacles
1
3
4
. Auxiliary power is not affected
by weld output.
1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 30 A AC Twistlock
Receptacle RC1
2
Receptacles supply 60 Hz singlephase power at weld/power speed.
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
. At least once a month, ru n e n-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker .
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker .
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
TM-4412 Page 20 D502K 5+4
191 624
SECTION 7 – MAINTENANCE
7-1. Maintenance Label
D502K 5+4
TM-4412 Page 21
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
7-2. Routine Maintenance
Wipe Up
Spills.
8 h
50 h
Recycle
engine
fluids.
Y Stop engine before maintaining.
. See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
* To be done by Factory Authorized Service Agent.
Coolant
Full
OIL
Full
Check Fluid
Levels. See
Section 4-5.
Clean Air Filter.
See Section 7-3.
Check Fuel Lines
And Connections.
Change Oil. See
Section 7-6.
100 h
200 h
Check Air Cleaner
Hoses For Cracks
And Loose Clamps.
Clean And
Tighten
Battery
Connections.
Clean An d
Tighten Weld
Terminals.
1/2 in.
(13 mm)
Change Oil Filter.
See Section 7-6.
Service More Often
In Dirty Conditions.
Check
Belt
Tension.
TM-4412 Page 22 D502K 5+4
Check
Radiator
Hoses And
Clamps.
250 h
Replace
Unreadable
Labels.
500 h
SLUDGE
Replace Fan Belt.
Check And
Clean Spark
Arrestor. See
Section 7-4.
Replace Secondary Fuel
Filter. See Section 7-6.
FUEL
Drain Sludge
From Fuel
Tank. See
Section 7-6.
800 h
1000 h
Check Valve
Clearance.*
Air Hose
Clean Radiator
Exterior.
Repair Or
Replace
Cracked
Cables.
Replace Primary
Fuel Filter. See
Section 7-6.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
OR
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
1500 h
Clean/Set
Injectors.*
1 Year
Replace Air
Filter Element(s).
See Section 7-3.
2 Years
Replace Radiator
Coolant And Hoses.
See Section 7-7.
D502K 5+4
TM-4412 Page 23
7-3. Servicing Air Cleaner
Keep nozzle
2 in (51 mm)
from element.
Blow Inspect
Optional
Y Stop engine.
Y Do not run engine without air
2
41 3
cleaner or with dirty element. E ngine damage caused by using a
damaged element is not covered
by the warranty.
. The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
damage when determining whether
to clean or replace the primary element.
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Replace primary element yearly or after six
cleanings.
1 Housing
2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Y Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if i t has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
TM-4412 Page 24 D502K 5+4
aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B
7-4. Inspecting/Cleaning Optional Spark Arrestor
3
1
2
Y Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe With Raincap
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Y Stop engine and let cool.
Reinstall cleanout plug.
Notes
Tools Needed:
3/8 in
Ref. 206 212-A / 803 122
D502K 5+4
TM-4412 Page 25
7-5. Adjusting Engine Speed
Y Stop engine and let cool.
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine no
load speed with a tachometer or frequency me t e r (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
Turn Process/Contactor Control
switch to Stick – Electrode Hot
position.
1 Engine Speed Adjustment
Screw
2 Locking Nut
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
. Do not set engine speed higher
than specified.
3 Engine Shutdown Lever
Use lever to stop engine if Engine
Shutdown switch does not work.
Y Stop engine.
Close door.
1850 rpm Max.
(61.6 Hz)
1
2
Tools Needed:
TM-4412 Page 26 D502K 5+4
3
803 123-A
7-6. Servicing Fuel And Lubrication Systems
Tools Needed:
5
3
Right Side
Y Stop engine and let cool.
Y After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter (In-Line)
5 Secondary Fuel Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
maintenance label for oil/filter change information.
D502K 5+4
1
To drain water from fuel system:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clockwise. Bleed air from fuel system according
to engine manual.
Inspect fuel line, and replace if cracked or
worn.
To replace secondary fuel filter:
See engine manual.
Close doors.
6
4
2
Ref. 800 159-E / Ref. 802 170 / 803 123-A
To drain sludge from fuel tank:
Y Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
Y Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining fuel tank.
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
TM-4412 Page 27
7-7. Servicing Engine Cooling System
2
Y Stop engine and let cool.
1 Radiator Cap
2 RAdiator Air Bleed Screw
3 Radiator Drain Cock
Drain engine coolant according to
procedure i n engine manual.
Add engine coolant according to
procedure in Section 4-6.
Tools Needed:
3/8 in
1
TM-4412 Page 28 D502K 5+4
3
Ref. 803 123-A / 803 136
7-8. Overload Protection
Y Stop engine.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and auxiliary power is low or
stops entirely . If F1 continues to open,
check integrated rectifier SR1, capacitor C9, the rotor, and brush connections.
If F2 opens, weld output stops. 4 kVA/
kW auxiliary power is still available. If
F2 continues to open, check field current regulator board PC1, the rotor,
and brush connections.
21
7
6
4
8
3 Circuit Breaker CB4 (Not Shown)
4 Circuit Breaker CB5
5 Circuit Breaker CB10 (Not
Shown)
6 Circuit Breaker CB11
7 Circuit Breaker CB12
8 Circuit Breaker CB13
CB4 protects the welding arc drive
(dig) circuit. If CB4 opens, the electrode may stick to the workpiece more
frequently during low voltage (short arc
length) conditions. CB4 automatically
resets when the fault is corrected. If
CB4 continues to open, check transformer T1, and integrated rectifiers
SR4 and SR5.
CB5 protects the 24 volt ac output to
remote receptacle RC14, and 24 volt
output to field current regulator board
PC1. If CB5 opens, weld output and 24
volt outpu t t o R C14 stops. If CB5 continues to open, check remote controls
connected to RC14, and circuit board
PC6 (see Section 10-5).
CB10 protects the engine battery circuit. If CB10 opens, the engine will not
crank. CB10 automatically resets
when the fault is corrected. If CB10
continues t o open, check fuel solenoid
FS1. Also check for wire(s) shorted to
ground.
CB11 protects the control box wiring
harness. If CB11 opens, weld output
stops (auxiliary power is still available). If CB11 continues to open,
check field current regulator board
PC1, and also verify wire 113 is not
shorted to ground (see Section 10-7).
CB12 protects the field flashing circuit.
If CB12 opens, the generator may not
excite at start-up and weld and auxiliary power output may not be available.
If CB12 continues to open, check field
current regulator board PC1 (see Section 10-7).
CB13 protects the 115 volt ac output to
remote receptacle RC14. If CB13
opens, 115 volt output to RC14 stops.
If CB13 continues to open, check remote controls connected to RC14, and
circuit board PC6 (see Section 10-5).
Press button to reset breaker.
D502K 5+4
803 123-A / 802 170-D / Ref. 802 313
TM-4412 Page 29
SECTION 8 – THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
fields.
2 Control Relays CR2, CR5
CR2 energizes at start-up to supply
power to the fuel solenoid.
CR5 energizes at start-up to supply
power to PC1.
3 Main/Exciter Revolving Fields
Turn at 1850 rpm maximum for weld
and power. The speed and excitation
current of the field coils determine
voltages in s t a t o r w i n d i n g s .
4 Stator Windings
Supply power to exciter, auxiliary
power, and weld circuits.
5 Fuses F1, F2
Protect aux. stator (exciter) windings
from overload.
6 Integrated Rectifier SR1
Changes a c output of stator windings
to dc to supply excitation current to
the exciter revolving field.
7 Voltage/Amperage Adjust
Control R1
Adjusts voltage/amperage within
range selected by S3.
8 Field Current Regulator Board
PC1
Adjust weld output by changing revolving filed current after comparing
feedback to voltage/amperage setting of R1 .
9 LED Board PC9
Monitors power, remote control,
command, engine rpm, and field excitation inputs to PC1.
10 Circuit Breakers CB5, CB13
Protects PC6/RC14 from overload.
11 Filter Board PC6/Remote 14
Receptacle RC14
PC6 protects unit from high frequency and excess voltage caused by a
damaged remote control cable.
RC14 connects remote voltage/amperage and contactor control to unit.
12 Process/Contactor Control
Switch S6
Selects weld process and weld output on/off control (W eld Terminals Always On or Weld Terminals Remotely Controlled).
11
Filter Board
PC6/Remote
Receptacle RC14
12
Process/
Contactor Switch S6
Remote
2
Control Relay
CR2
13
Revolving
Engine
Fields
(Rotor)
Electrode
6
Integrated
Hot
Rectifier
SR1
10
Circuit
Breakers
CB5, CB13
13
Voltage/
Amperage
Adjust Control
Switch S5
7
Voltage/
Amperage
Adjust
Control R1
2
Control Relay
CR5
5
Fuse F1
4
Exciter
Stator Windings
Auxiliary Power
24
Transformer
9
LED Board PC9
8
Field
Current
Regulator
Board
PC1
5
Fuse F2
Weld
T1
TM-4412 Page 30
25
Integrated
Rectifiers
SR4, SR5
Figure 10-1. Functional Diagram
D502K 5+4
♦
OCV
Feedback
♦♦
22
Voltmeter
V1
17 18 19
14
Amperage
Range
Switch S3
Reactor
Z1
15
Circuit Breakers
CB1, CB2
22
Ammeter
21
AC Or DC Control Circuits
3φ Power
Weld Current Circuit
Either Mechanical Coupling
Or External Circuits
Magnetic Coupling
Optional
A2
Main
Rectifier
SR3
♦
Polarity/AC
Selector
Switch S13
20
HF Filter
Board PC3
13 Voltage/Amperage Adjust Control
Switch S5
Selects Panel or Remote voltage/amperage control.
14 HF Filter Boards PC4, PC5
Protect unit from high frequency.
15 Circuit Breakers CB1 And CB2
Protect AC receptacles RC1 and
GFCI1 from overload.
16 AC Receptacles RC1 And GFCI1
Provide connection points and power
for auxiliary equipment.
17 Reactor Z1
Tapped reactor limits weld output and
provides coarse ranges.
18 Amperage Range Switch S3
Selects coarse range of weld output
from Z1.
19 Main Rectifier SR3
Changes ac weld output to dc.
20 HF Filter Board PC3
Protects main rectifier from high fre-
quency and voltage spikes, and provides OCV feedback signal to PC1.
21 Polarity/AC Selector Switch S13
Selects ac weld output or polarity of dc
weld output.
22 Voltmeter V1, Ammeter A1
Display weld voltage and current.
23 Electrode And Work Weld Output
Terminals
Provide weld output. Without optional
Polarity/AC Selector switch S13 terminals are labeled negative (–) and positive (+).
24 Transformer T1
Supplies power to arc drive (dig) circuit.
Arc drive circuit only active in Stick
mode.
25 Integrated Rectifiers SR4, SR5
Change ac output of stator windings to
dc to supply power to arc drive (dig)
circuit.
HF Filter
16
AC
Receptacles
RC1, GFCI1
Board PC4
14
HF Filter
Board PC4
23
Electrode
Weld Output
Terminal
Electrode Work
14
HF Filter
Board PC5
23
Work
Weld Output
Terminal
TM-4412 Page 31D502K 5+4
SECTION 9 – EXPLANATION OF ELECTRICAL PARTS
9-1. Safety Precautions – Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.
D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
9-2. Explanation Of Electrical Parts
P ART NAME FUNCTION PICTURE CIRCUIT SYMBOL
elect_parts 1/01
CAPACITOR A device that stores electrical energy. Large
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk”
capacitors can be used for HF protection.
CIRCUIT BREAKER A protection device that breaks a circuit when
current levels exceed its rating. Unlike a fuse
that needs to be replaced when blown, a
circuit breaker can be reset.
DIODE A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
FUSE A protection device, usually an enclosed
piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
HALL DEVICE Produces a small DC voltage proportional to
the current it is sensing (usually welding
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
RESISTOR A device which resists the flow of electric
current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
POLARIZED NON-POL.
C1 C1
CB1
D1
F1
HD1
FIXED
FIXED TAPPED
R1
R1
POTENTIOMETER
OR
RHEOSTAT
Both devices have a moveable brush that
makes contact along a resistor, allowing you
to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
TM-4412 Page 32
VARIABLE
R1
D502K 5+4
P ART NAME CIRCUIT SYMBOLPICTUREFUNCTION
FAN MOT OR This device provides cooling of the internal
parts of a welding power source.
VARISTOR A protection device whose resistance is
dependent on the voltage applied to it. In
normal operation it has a high resistance;
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
GAS OR WATER
SOLENOID
(VALVE)
RELAY––COIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
These are electromechanical devices used to
start or stop the flow of shielding gas or
water.
This is an electromechanical device whose
contacts change state (the normally open
points close and the normally closed points
open) when proper voltage is applied to the
coil. These contact points in turn may control
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show
the contact points in the power off state.
FM
VR1
GS1
OR
WS1
COIL
CR1 CR1
NRM OPEN
POINTS
NRM CLOSED
POINTS
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is a switch that closes its normally open
contacts (or opens its normally closed
contacts) when a preset temperature is
reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when
needed and shutting off the output of a
welding power source if it is overheating.
CONTACTOR A heavy duty relay. Usually used to make
and break the welding arc or primary power.
PILOT LIGHT A light located on the front panel which
indicates if the machine is on or off.
STABILIZER/
REACTOR
When placed in a DC circuit, the inductor or
stabilizer as it is usually called, will oppose
any change in existing current. It is therefore
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
NRM OPEN
W
NRM OPEN
POINTS
TP1TP1
NRM CLOSED
COIL
W
1
PL
Z1
L1
TM-4412 Page 33D502K 5+4
P ART NAME CIRCUIT SYMBOLPICTUREFUNCTION
MOTOR A device that is typically used to feed wire in
a MIG welding system.
SHUNT A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
MOSFET A device that is used as an “electronic
switch.” When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
to control a relay, the speed of a motor, or
even the output of a welding machine.
IGBT A device that is used as an “electronic
switch.” When a signal is applied to the gate
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically
used in “Invertor” designed welding machines
to control the welding output.
BRUSHES/SLIP
RINGS
Components that allow electrical connections
between stationary and rotating contacts.
SLIP
RINGS
G1 (B1)
SHUNT
G
AS
B1
D
S
C1
E1
TERMINAL STRIP An insulated connection point for wires. They
are used for the ease of making multiple
connections and can be a convenient point
for making electrical checks when
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
SWITCH A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
BRUSHES
42 42 104 105 74
1T
ABCDE
SPDTSPST
DPDTDPST
TM-4412 Page 34
D502K 5+4
PART NAME CIRCUIT SYMBOLPICTUREFUNCTION
SCR A Silicon Controlled Rectifier (SCR) is an
electrical device with three connections,
anode, cathode, and gate. It will allow current
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to
control the output to a load such as a welding
arc.
THERMISTOR A thermally sensitive resistor. The resistance
of a thermistor changes with a change in
temperature. Primarily used for “Fan on
Demand” and “Thermal Shutdown” circuits.
TRANSFORMER A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
INTEGRATED
BRIDGE
An arrangement of four diodes used to
change AC to DC.
RECTIFIER
SPARK GAP The arrangement of two electrodes between
which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding.
AC
K
G
A
RT1
OR
TH1
T1
AC
+
+
–
AC
_
AC
G
CURRENT
TRANSFORMER
A transformer that produces an AC voltage
used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current.
CT1
OR
CT1
TM-4412 Page 35D502K 5+4
SECTION 10 – TROUBLESHOOTING
10-1. Troubleshooting Tables
A. Welding
Trouble Remedy
. See Section 10-2 for test points and
values and Section 14 and following
for parts location.
No weld output; auxiliary power output
okay.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Weld
Terminals Remotely Controlled position and connect remote contactor to optional Remote 14 receptacle
RC14 (see Sections 4-9, 5-3 and 5-4).
Check position of Amperage Range switch S3.
Check position of optional Polarity/AC Selector switch S13.
Reset circuit breaker CB11 (see Section 7-8).
Reset circuit breaker CB5 (see Section 7-8). Check for faulty remote device connected to RC14.
Check fuse F2, and replace if open (see Section 7-8).
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Check connector board PC6 and connections, and replace PC6 if necessary (see Section 10-5).
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-7).
Disconnect leads 105 and 108 from rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Reset circuit breaker CB12 (see Section 7-8).
Check fuses F1 and F2, and replace if open (see Section 7-8).
Check integrated rectifier SR1, and replace if necessary.
Check capacitor C9, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Erratic weld output. Use dry, properly stored electrodes.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Check and tighten connections inside and outside unit.
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Check main rectifier SR3, and replace if necessary.
TM-4412 Page 36
D502K 5+4
Trouble Remedy
High weld output. Check position of Amperage Range switch S3 and Voltage/Amperage Adjust control R1.
Check engine speed, and adjust if necessary (see Section 7-5).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Electrode sticks to the workpiece more
frequently during low voltage (short arc
length) conditions.
Low weld output. Check engine speed, and adjust if necessary (see Section 7-5).
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 7-5).
No remote fine amperage or voltage
control.
Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 7-8).
Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.
Check integrated rectifiers SR4 and SR5, and replace if necessary.
Check fuses F1 and F2, and replace if open (see Section 7-8).
Check integrated rectifier SR1, and replace if necessary.
Check capacitor C9, and replace if necessary.
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Place Voltage/Amperage Adjust Control switch S5 in Weld Terminals Remotely Controlled position.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Repair or replace remote control device.
Wire feeder does not work with welding
generator.
Low CV weld output. Set Amperage Range switch S3 to highest range.
Min or max CV weld output only. Check position of Voltage/Amperage Adjust control R1 and Voltage/Amperage Adjust Control switch S5.
Reset circuit breaker CB5 or CB6 (see Section 7-8).
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Repair or replace wire feeder.
Repair or replace remote control device.
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit. Feed-
back voltage should be the same as weld terminal open circuit voltage (see Section 10-2).
B. Auxiliary Power
Trouble Remedy
No auxiliary power output; weld output
okay.
Reset receptacle circuit breakers.
Check resistance of auxiliary power windings between leads 81 and 84. Replace exciter stator (aux. stator) if necessary .
TM-4412 Page 37D502K 5+4
Trouble Remedy
No auxiliary power output or weld output. Disconnect equipment from auxiliary power receptacles during start-up.
Reset circuit breaker CB12 (see Section 7-8).
Check fuses F1 and F2, and replace if open (see Section 7-8).
Check integrated rectifier SR1, and replace if necessary.
Check capacitor C9, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
High output at auxiliary power
receptacles.
Low output at auxiliary power
receptacles.
Check engine speed, and adjust if necessary (see Section 7-5).
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
Check engine speed, and adjust if necessary (see Section 7-5).
Check fuse F1, and replace if open (see Section 7-8).
Check integrated rectifier SR1, and replace if necessary.
Check capacitor C9, and replace if necessary.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 7-8).
Check engine wiring harness and components.
Check engine wiring harness plug connections.
Check continuity of Engine Start/Preheat switch S1, and replace if necessary.
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR2 if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coils. Replace
FS1 if necessary.
Check fuel pump (see engine manual).
Air in fuel system. See engine manual.
TM-4412 Page 38
D502K 5+4
Trouble Remedy
Engine starts, but stops when Start/Preheat switch S1 is released.
Engine hard to start in cold weather. Turn Start/Preheat switch S1 to Preheat position before starting (see Section or 5-1).
Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low (see Sections 4-5).
Engine slowly stopped and cannot be
restarted.
Check coolant level. Automatic shutdown system stops engine if engine temperature is too high (see Sections 4-5).
Check timer relay T for proper coil voltage and connections. Check continuity of coil and condition of contacts. Replace timer relay T if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Check glow plug and related wiring (see engine manual).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 7-1).
Check coolant level. Automatic shutdown system stops engine if engine temperature is too high (see Sections 4-5).
Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR2 if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coils. Replace
FS1 if necessary.
Check fuel level.
Check engine air and fuel filters (see Sections 7-3 and 7-6).
See engine manual.
Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 13).
TM-4412 Page 39D502K 5+4
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
V3, R3
V1, R1
V2, R2
V4, R4
Adjust R3
See Section
10-5 for
PC6 data
See Section
4-9 for RC14
information
V5, R5
V6, R6
according to
Section 10-12
V7
V18
V17
V8, R7
V9, R8
I2
V19
I1
TM-4412 Page 40
V20
V21
V16
Timer
Relay T
V14,
R12
V15
R13
D502K 5+4
V10,
R9
V12, R11
V11, R10
See Section 8 for
PC3 information
V22
V24
V23
See Section 8
for PC4, PC5
information
V13,
Waveforms
A and B
See
Section 10-4
for waveforms
Engine oil pressure
latching
relay CR1
Engine temp.
latching relay
CR2
PC1 power
supply relay
CR5
206 628-A
TM-4412 Page 41D502K 5+4
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)
Test Equipment Needed:
Voltage Readings
a) Tolerance –
b) Condition – 70
machine (no warm-up); no load
c) Reference – single arrow: reference
to circuit common (lead 42); double
arrow: reference to points indicated
d) Process/Contactor Control switch S6
in Weld Terminals Always On – CC
Stick position unless noted
e) Wiring Connections – see Section 12
V1 126 – 130 volts ac
V2 126 – 130 volts ac
V3 252 – 260 volts ac
V4 27 volts ac
V5 101 volts ac
V6 175 volts ac
V7 +135 volts dc
V8 + 89 volts dc
V9 +89 volts dc (S6 in Weld Terminals Always
On –Stick position)
+33 volts dc (S6 in Weld Terminals Always
On–Scratch Start TIG position)
+11.5 to 40.5 volts dc from min to max of
R1 (S6 in Weld Terminals Always On –
MIG position)
V10 69 volts ac (R1 at max.)
V11 69 volts ac (R1 at max.)
V12 69 volts ac (R1 at max.)
V13 +89 volts dc (S6 in Weld Terminals Always
On – Stick position)
47 volts dc (S6 in Weld Terminals Always
On – Scratch Start Tig position)
+16 to 56 volts dc from min to max of R1
(S6 in Weld Terminals Always On – MIG
position)
V14, +12 volts dc with Start/Preheat switch S1 in
V15, Preheat position
V16
V17 0 to +10 volts dc from min to max of R1
V18 +12 volts dc
V19 0 to +10 volts dc from min to max of R1
V20 +12 volts dc
V21 +12 volts dc
V22 258 volts ac with Process/Contactor
Controlswitch S6 in Stick position
V23, 18 volts ac with Process/Contactor
V24 Control switch S6 in Stick position
±10% unless specified
°F (21°C); cold
Resistance Values
a) Tolerance – ±10% unless
specified
b) Condition – 70
°F (21°C); cold
machine (no warm-up)
c) Wiring Connections – see
Section 12
d) Stop engine before checking
resistance
R1 thru R6 Less than 1 ohm
R7 18.5 ohms
R8 14.2 ohms
R9 thru R11 Less than 1 ohm
R12 15 ohms
R13 Less than 1 ohm
Amperage Readings
a) Tolerance – ±5% unless specified
b) Condition – 70
°F (21°C); cold
machine (no warm-up); no load
c) Process/Contactor Control
switch S6 in Weld Terminals
Always On – CC Stick position
unless noted
I1 6.3 amps dc
I2 4.3 – 4.6 amps dc
TM-4412 Page 42
D502K 5+4
10-4. Waveforms For Section 10-2
1 ms 50 V
gnd
A. DC/CC Open-Circuit Voltage, Voltage/
Amperage Adjust Control R1 At Maximum
1 ms 10 V
gnd
B. DC/CC Output, 28 Volts DC, 200 Amperes,
Amperage Range Switch S3 At 125-400
Position (Resistive Load)
Test Equipment Needed:
TM-4412 Page 43D502K 5+4
10-5. Filter Board PC6 Testing Information
Y Stop engine.
See Section 10-6 for specific values during testing. Voltage read-
ings tolerance ±10%.
TM-4412 Page 44
Test Equipment Needed:
803 208 / 192 998
D502K 5+4
10-6. Filter Board PC6 Test Point Values
PC6 Voltage Readings
Receptacle Pin Value
RC2 1 Not used
2 115 volt ac input with respect to pin RC2-10
3 24 volt ac input with respect to pin RC2-10
4 24 volt ac output with respect to pin RC2-10
5 Contactor control circuit, 24 volt ac input with contact closure to pin RC2-9 and closure on RC14 be-
tween pins A and B or pins I and J
6 Command reference, 10 volt dc input
7 Command common
8 Remote command signal output, 0 to +10 volts dc input from min to max of remote voltage/amperage
control
9 Circuit common for 24 and 115 volt ac contactor control circuits
10 Circuit common for 24 and 115 volt ac circuits
a) Tolerance –
±10% unless specified
b) Reference – to circuit common
(lead 42) unless noted
c) Condition – no load
d) Process/Contactor Control switch
S6 in Weld Terminals Always On –
CC Stick position
TM-4412 Page 45D502K 5+4
10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9
Determine the condition of field current regulator board PC1 by observing the LED’s on LED board
PC9 (in control box).
. Do not open the PC1 sealed
case to service PC1. If PC1 is
not working properly, replace
the entire PC1 module.
1
3
Be sure plugs are secure. See Section 10-8 for diagnostic information
and specific values during testing.
1 Field Current Regulator Board
PC1 Module
2 LED Board PC9
3 Diagnostic LED’s (See Sec-
tion 10-8)
2
Test Equipment Needed:
TM-4412 Page 46
802 421-C / 192 226-A
D502K 5+4
10-8. Using Diagnostic LED’s On LED Board PC9
NOTE
The LED’s on circuit board PC9 monitor all critical input voltages to field current
regulator board PC1.
If PC9 Power LED, Output On/Off LED, and AC Input LED are on with
Process/Contactor Control switch S6 in Weld Terminals Always On - CC Stick
mode and engine running at weld/power speed, 89 volts dc should be present at
brush leads 105 and 108. This indicates field current regulator board PC1 is
functioning normally.
LED Status Self-Test
POWER On Indicates +12 volts dc is present to energize PC1.
Off If LED is off:
Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR5 if necessary.
Reset circuit breaker CB10 and/or CB11.
Check for loose electrical connections to PC1.
Check for 12 volt dc supply voltage to PC1. If voltage is low, check battery or engine charging system.
a) Condition – no load; weld/power
rpm unless noted
b) Voltage/Amperage Adjust Con-
trol switch S5 in Panel position
b) Reference – to circuit common
(lead 42) unless noted
OUTPUT
ON/OFF
COMMAND On Indicates 0 to +10 volts dc input from min. to max. of V oltage/Amperage Adjust control R1 with Voltage/
RPM
LIMIT
. LED normally
off at weld/
power speed)
On Indicates 24 volts ac input with Process/Contactor Control switch S6 in W eld Terminals Always On posi-
tion, or with S6 in a Weld Terminals Remotely Controlled position with remote contactor closed.
Off If LED is off:
Place Process/Contactor Control switch S6 in Weld Terminals Always On position, or place S6 in Weld
Terminals Remotely Controlled position and connect remote contactor to remote receptacle RC14.
Reset circuit breaker CB5.
Check filter board PC6 and connections, and replace if necessary (see Section 10-5).
Voltage/Amperage Adjust Control switch S5 in Panel position.
Off If LED is off:
And Power LED is on, check that Voltage/Amperage Adjust control R1 is not at min.
And Power LED is on, check and tighten connections to Voltage/Amperage Adjust control R1.
And Power LED is on, check voltage at Voltage/Amperage Adjust control R1 (see Section 10-2). If correct
voltage i s not present, check connections to PC1.
And Power LED is on, check resistance and connections of Voltage/Amperage Adjust control R1; R1 is
0 to 1000 ohms ±10%. Replace R1 if necessary.
On Indicates engine speed is less than 1704 rpm (approximately).
If LED is on:
And AC Input LED is on, check engine weld/power speed and adjust if necessary.
And AC Input LED is off, check fuse F2, and replace if open.
And AC Input LED is off, reset circuit breaker CB12.
Off Indicates engine speed is above 1704 rpm (normal operation).
AC INPUT On Indicates + 175 volts ac input from field excitation circuit.
Dim or Off If LED is off, power LED is on, and normal ac voltage is present at ac receptacles (see Section 10-2):
Check fuse F2, and replace if open.
Reset circuit breaker CB12.
TM-4412 Page 47D502K 5+4
10-9. LED Board PC9 Testing
Be sure plugs are secure. See Section 10-10 for specific values during
testing.
1 LED Board PC9
1
Test Equipment Needed:
TM-4412 Page 48
803 208 / 192 226-A
D502K 5+4
10-10. Diagnostic LED’s On LED Board PC9
PC9 Voltage Readings
Receptacle Pin Value
PLG13 1 Power LED, +2 volts dc input
To test power LED, apply +2 volts dc to PLG13-1 and connect negative (–) side of power supply to
PLG13-8. LED lights if okay.
2 Not used
3 Not used
4 Not used
5 AC input LED, +1.85 volts dc input with respect to pin PLG13-10 when weld exciter voltage is
present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (–) side of power sup-
ply to PLG13-5. LED lights if okay.
6 Output on/off LED, 0.13 volts dc input with contactor off; + 2 volts dc input with contactor on.
To test output on/off LED, apply +2 volts dc to PLG13-6 and connect negative (–) side of power sup-
ply to PLG13-8. LED lights if okay.
7 Command LED, 0 to 2 volts dc input from min to max of Voltage/Amperage Adjust control R1.
To test command LED, apply +2 volts dc to PLG13-7 and connect negative (–) side of power supply
to PLG13-8. LED lights if okay.
8 Circuit common
9 RPM Limit LED, +10.5 volts dc input at 1850 rpm; voltage decreases as engine speed decreases.
LED goes on when engine speed is less than 1704 rpm (approximately).
To test rpm limit LED, apply +2 volts dc to PLG13-8 and connect negative (–) side of power supply to
PLG13-9. LED lights if okay.
10 AC Input LED, +1.85 volts dc input with respect to pin PLG13-5 when weld exciter voltage is present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (–) side of power sup-
ply to PLG13-5. LED lights if okay.
a) Tolerance –
±10% unless
specified
b) Reference – to circuit common
(lead 42) unless noted
c) Condition – no load; weld/power
rpm unless noted
d) Process/Contactor Control switch
S6 in Weld Terminals Always On –
CC Stick position
. Do not exceed recommended voltage
when testing LED’s or circuit board may be
damaged.
TM-4412 Page 49D502K 5+4
10-11.Replacing Brushes And Cleaning Slip Rings
1
Y Stop engine.
1 Auxiliary Power Panel
Remove screws from panel. Tilt
panel forward.
2 Spring Clip
3 Brush
4 Brush Holder Assembly
Squeeze end of spring clip to re-
move clip and brush from brush
holder assembly. Remove and inspect all three brushes.
Replace brushes if damaged, or if
brush is a t o r near minimum length.
5 Slip Rings
Visually inspect slip rings. Under
normal use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Reinstall auxiliary power panel.
Y Stop engine.
5
4
Minimum Length:
5/8 in (16 mm)
Replace
Damaged Brushes
2
New Length: 1-1/4 in (32 mm)
3
Tools Needed:
TM-4412 Page 50
803 209
D502K 5+4
10-12.Checking Unit Output After Servicing
1
Y Stop engine before adjusting resistor R3.
2
Start engine and check engine
speed. Adjust engine speed if necessary (see Section 7-5).
1 Duplex Receptacles GFCI1
And RC1
2 Resistor R3
Turn Voltage/Amperage Adjust
control R1 to max. Place Process/
Contactor Control switch S6 in
Weld Terminals Always On – CC
Stick position.
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts ac present at
GFCI1 and 252 to 260 volts ac at
RC1.
If correct voltage is not present,
stop engine and reconnect lead 102
and/or lead 106 to different taps on
R3.
. Connect R3 so at least half of
resistor length is in circuit.
Start engine and check GFCI1 and
RC1 voltage. If necessary, change
R3 connections until correct voltage is obtained at receptacles without exceeding 4.6 amperes dc exciter revolving field current (see
Section 10-2).
Check open-circuit voltage across
weld output terminals. There
should be 90 volts dc present. If
correct voltages are not present, repeat troubleshooting procedures in
Section 10-1.
Y Stop engine.
Allow engine to cool, and then complete pre-operational checks in
table.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-5).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Test Equipment Needed:
Tools Needed:
803 210 / 803 201
TM-4412 Page 51D502K 5+4
SECTION 11 – DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
3
2
Use Section 10 to determine if trouble
is in exciter stator, stator, rotor , engine
or combination of these components.
Y Stop engine and let cool. Dis-
connect battery negative (–)
cable.
Remove exhaust pipe, fuel cap, and
top cover. Reinstall fuel cap. Remove
side panels and door(s). Retain all
hardware.
1 Control Box
Disconnect plugs from control box.
Remove box.
. T o aid in reassembly, mark leads
before disconnecting. See lead
list summary in Section 12 for
connection information.
Disconnect:
F stator weld leads from Amper-
age Range switch S3
F stator exciter leads from termi-
nal strip 1T
1
4
F resistor R3 leads
F weld output terminal leads
2 Front And Center Upright
Assembly
3 Reactor Z1 Lifting Eye
The entire assembly will be removed
together. Remove bolts securing uprights to base. While supporting assembly at front panel and reactor lifting eye, evenly lift and remove
assembly.
4 Engine
5 Flywheel Housing
6 Front Generator Mounts
Support engine under flywheel hous-
ing with a 1 x 3 x 30 in (25 x 76 x 762
mm) metal bar.
. Do not support engine on fuel
tank or under oil pan.
Remove front generator mounts. Go
to Section 11-2.
TM-4412 Page 52
5
6
802 431-C
D502K 5+4
11-2. Disassembly Of Generator
A
4
1
3
2
C
A
D
D
B
Torques:
A 31 ft lb (42 N.m)
B 100 in lb (11 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
E 42 ft lb (57 N.m)
E
803 204-A
Y Do not damage stator or rotor win-
dings during this procedure.
1 Stator
With engine properly supported with metal
bar (see Section 11-1), remove hardware securing stator to engine. Remove the following
parts as needed:
2 Endbell
3 Exciter Stator
Exciter stator comes off with endbell.
4 Rotor
If engine must also be removed, remove en-
gine from base mounts.
Reassembly Instructions:
Reinstall engine and generator parts as
needed using torque values in table.
Reinstall upright assembly. Reconnect fuel
line.
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative (–) battery cable. Reinstall panels, door, and exhaust pipe.
TM-4412 Page 53D502K 5+4
Notes
TM-4412 Page 54
D502K 5+4
SECTION 12 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
Model Serial Or Style Number
D502K 5+ 4 LC110463 and following 206 628-A See Table 12-1
Circuit Board PC4, PC5
(HF Filter)
Circuit Board PC3
(HF Filter)
Circuit Board PC6
(HF Filter )
Circuit Board PC9
(LED)
LC110463 and following 189 746
LC110463 and following 188 607
LC110463 and following 192 997
LC110463 and following 192 227-A
Circuit
Diagram
Wiring
Diagram
TM-4412 Page 55D502K 5+4
Figure 12-1. Circuit Diagram For D502K 5+4 Effective With Serial No. LC110463 And Following
TM-4412 Page 56
D502K 5+4
206 628-A
TM-4412 Page 57D502K 5+4
GND
1
2
3
4
5
C1
C2
C3
C4
C5
COM
189 746
Figure 12-2. Circuit Board PC4, PC5 (HF Filter) Effective With Serial No. LC110463 And Following
19A
27
37A
37B
17
30A
Figure 12-3. Circuit Board PC3 (HF Filter) Effective With Serial No. LC110463 And Following
TM-4412 Page 58
C4
C2
19B
19C
C3 C1
R1
RV1
30C
C5 C6
30B
188 607
D502K 5+4
Figure 12-4. Circuit Board PC6 (HF Filter) Effective With Serial No. LC110463 And Following
192 997
Figure 12-5. Circuit Board PC9 (LED) Effective With Serial No. LC110463 And Following
192 227-A
TM-4412 Page 59D502K 5+4
Table 12-1. Lead List Summary For D502K 5+4 Eff w/LC110463 And Following
. T able shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections
––––B RC6 (2) – S3 (2)
––––H RC6 (1) – S3 (1)
0010A T1 SEC TO SR4 (AC)
0011A STATOR TO EXIT
0012A #1 COIL TO RANGE SWITCH
0013A #1 COIL TO RANGE SWITCH
0014A #1 COIL TO RANGE SWITCH
0015A #1 COIL TO RANGE SWITCH
0016A #1 COIL TO RANGE SWITCH
0017A #1 COIL TO RECTIFIER
0017A PC3 TO BUS BAR
0018A T1 SEC TO SR4 (AC)
0019A PC3 TO HEA T SINK (+)
0019B PC3 TO LEAD 19 FROM PC1 (E2)
0019C PC3 TO LEAD 19 FROM VOLTMETER (+)
0019D SR3 (+) TO WELD TERMINAL (+)
0019E SR4 (+) TO SR3 (+)
0019F SR5 (+) TO SR3 (+)
0019J PC1 (PLG8–E2) TO LEAD 19 FROM PC3
0021A STATOR TO EXIT
0022A #2 COIL TO RANGE SWITCH
0023A #2 COIL TO RANGE SWITCH
0024A #2 COIL TO RANGE SWITCH
0025A #2 COIL TO RANGE SWITCH
0026A #2 COIL TO RANGE SWITCH
0027A #2 COIL TO RECTIFIER
0027A PC3 TO BUS BAR
0030A PC3 TO HEAT SINK (–)
0030B PC3 TO LEAD 30 FROM PC1 (E1)
0030C PC3 TO LEAD 30 FROM VOLTMETER (–)
0030D SHUNT (OUTSIDE) TO LEAD 30 FROM
AMMETER
0030E SHUNT (INSIDE) TO LEAD 30 FROM AMMETER
0030F SR3 (–) TO WELD TERMINAL (–)
0030G SR4 (–) TO SR3 (–)
0030H SR5 (–) TO SR3 (–)
0030J PC1 (PLG8–E1) TO LEAD 30 FROM PC3
0031A STATOR TO EXIT
0032A #3 COIL TO RANGE SWITCH
0033A #3 COIL TO RANGE SWITCH
0034A #3 COIL TO RANGE SWITCH
0035A #3 COIL TO RANGE SWITCH
0036A #3 COIL TO RANGE SWITCH
0036A PC8 (PLG1–G1) TO PLG6 (3)
0036C RC6 (3) – S3 (3)
0037A #3 COIL TO RECTIFIER
0037A PC1 (PLG8–G2) TO LEAD 37 FROM SR3
0037A PC3 TO BUS BAR
0037B PC3 TO LEAD 37 FROM PLG3 (2)
0038A T1 SEC TO SR5 (AC)
0039A T1 SEC TO SR5 (AC)
0040A STARTER TO AMP METER (POS)
0041A AMP METER (NEG) TO CB10 (COPPER)
TM-4412 Page 60
0042AB BASE GROUND TO D10 (–)
0042AC CR5 (85) TO D10 (–)
0042AD FUEL SENDER TO BASE GROUND
0042AE GROUND CABLE TO OIL PRESSURE SWITCH
0042AF FUEL PUMP TO FUEL SENDER
0042BA SPLICE A TO SPLICE B
0042BB SPLICE T O D10 (NEG)
0042CC RC3 (2) TO LEAD 42JJ
0042DD SPLICE TO TIMER (NEG)
0042EE SPLICE TO HOUR MTER (NEG)
0042H PC1 (PLG8–F3) TO PC8 (PLG13–8)
0042JJ SPLICE TO LEAD 42 CC
0042K PC1 (PLG8–C1) TO PLG3 (2)
0042KK SPLICE TO LEAD 42 SS
0042L END BELL (BOTTOM–LEFT) – PC4 (GND)
0042L END BELL (BOTTOM–RIGHT) – PC5 (GND)
0042L END BELL (TOP–LEFT) – PC6(GND)
0042M ASSY TO TEMP GAUGE (5)
0042N GND STD (BASE) TO GND STUD (AUX PANEL)
0042P 1T (C–RIGHT) – GND STUD
0042R GFCI (GND) – GND STUD
0042S RC1 (GND) – GND STUD
0042SS SPLICE T O 42KK
0042T 076 (K) TO LEAD 42 FROM END BELL
0042U ASSY TO HOUR METER (–)
0042V ASSY TO FUEL GAUGE (5)
0043A START SWITCH (17) TO GLOW PLUGS
0043B START SWITCH JUMPER #17 TO #19
0043D S1 (19) TO D9 (–)
0043E GLOW PLUG TO FS1 (PULL)
0044A CR5 (87A) TO CB10 (SILVER)
0044B CB10 (SILVER) TO START SW (30)
0044C CB10 (SILVER) TO ALT (B)
0044H CR5 (87) TO TIMER (N.O.)
0044J CB10 (SILVER) TO CR1 (30)
0045A CR2 (30) TO FS1
0046A STOP SW (CENTER) TO CR 2 (87A)
0048A LEAD 48B TO S6 (9)
0054A CT2 TO CT1
0055A CT2 TO CT1
0060A D8 (POS) TO ALT (IND)
0061A D10 (+) TO CR1 (86)
0061B D8 (–) TO D9 (+)
0061C SPLICE TO HOUR METER (+)
0061CA D9 (+) TO D10 (+)
0061D SPLICE TO FUEL GAUGE (6)
0061E D8 (–) TO CR5 (86)
0061F TIMER (+) TO STOP SW (BOTTOM)
0061H SPLICE TO TEMP GAUGE (6)
0061J SPLICE TO TEMP GAUGE (2)
0061K FUEL PUMP TO CR1 (87A)
D502K 5+4
Table 12-1. Lead List Summary For D502K 5+4 Models Eff w/LC110463 And Following (Continued)
Lead Connections Lead Connections
0061M TIMER (C) T O D8 (NEG)
0061N D8 (–) TO CR2 (86)
0061P TIMER (POS) TO TIMER ”C” (COMMON)
0061Q STOP SW BOTTOM T O HOUR METER (POS)
0061R CR1 (87) TO D10 (POS)
0062A TEMP GAUGE (4) TO CR2 (85)
0064A STARTER SOLENOID TO START SW (50)
0066B LEAD FROM CT1 TO PC7 (D)
0067B LEAD FROM CT1 TO PC7 (G)
0068B S6 (10) TO CR6 (30)
0069A CR1 (85) TO OIL SENDER (S12)
0070A COOLENT SENDER TO TEMP GAUGE (3)
0071A FUEL GAUGE (3) TO FUEL SENDER
0081A EXCITER STATOR – 1T (A–LEFT)
0081B CB1 (BOTTOM) – 1T (A–RIGHT)
0081D EXCITER TO T1
0081E T1 PRI TO EXCITER ST ATOR
0082A EXCITER STATOR – 1T (B–LEFT)
0082B GFCI (N) – 1T (B–RIGHT)
0083A EXCITER STATOR – 1T (C–LEFT)
0083B PC6 (PLG14–10) TO (1T–83C)
0083D PC6 (PLG14–9) TO PC1 (PLG9–F2)
0084A EXCITER STATOR – 1T (D–LEFT)
0084B CB1 (BOTTOM) – 1T (D–RIGHT)
0084D EXCITER TO S6
0084E AUX STATOR TO S6 (11 )
0084F 1TD TO CB23
0085A CB2 (BOTTOM) – GFCI (HOT)
0085B CB2 (BOTTOM) – PC4 (5)
0086A CB1 (TOP) – RC1 (BOTTOM–RIGHT)
0086D CB1 (TOP) – CB2 (TOP)
0087AA CB23 T O PLG14 (2)
0088A CB1 (TOP) – RC1 (BOTTOM–LEFT)
0088B CB1 (TOP) – PC4 (4)
0089A EXCITER TO CB5 (TOP)
0098A S6 (12) TO CB4
0099A T1 PRI TO CB4
0100A EXCITER STATOR – PLG1 (1)
0100B RC1 (1) TO F1
0101A EXCITER STATOR – PLG1 (3)
0101B RC1 (3) TO SR1 (AC)
0102C SR1 (–) TO C9 (–)
0102D RC3 (4) TO C9 (–)
0102E R3 TO PLG3 (4)
0103A EXCITER STATOR – PLG1 (4)
0103B PC1 (PLG8–A1) TO PLG3 (6)
0103D RC3 (6) TO RC1 (4)
0104A EXCITER STATOR – PLG1 (6)
0104B RC1 (6) TO F2
0105A BRUSH (CENTER) – PLG1 (2)
0105B SR1 (+) TO C9
0105D RC3 (8) TO C9 (+)
0105E PC1 (PLG8–D1) TO PLG3 (8)
0105F RC1 (2) TO SR1 (+)
0106A BRUSH (FRONT) – PLG1 (5)
0106B RC1 (5) TO SPLICE
0106C RC3 (7) TO SPLICE
0106D CR4 (6) TO SPLICE
0106D R3 TO PLG3 (7)
0106E SPLICE (A) TO SPLICE (B)
0108A BRUSH (REAR) – PLG1 (8)
0108B RC1 (8) TO RC3 (9)
0108C PC1 (PLG8–A2) TO PLG3 (9)
0110A CB12 TO RC3 (1 1 )
0110B PC1 (PLG8–C2) TO PLG3 (11)
0111A CB12 TO CB11
0111B CB12 TO CR5 (30)
0113A CB11 TO RC3 (12)
0113B PC1 (PLG8–B1) TO PLG3 (12)
0116A PC6 (PLG14–8) TO PC1 (PLG9–B1)
0117A PC6 (PLG14–7) TO PC1 (PLG9–C3)
0118A PC6 (PLG14–6) TO PC1 (PLG9–B2)
0119A S6 (1) TO PC6 (PLG14–5)
0120A S6 (2) TO PC1 (PLG9–F1)
0121A S6 (3) TO PC6 (PLG14–4)
0121B PC6 (PLG14–3) TO CB5
0122A PC1 (PLG9–A1) TO S6 (5)
0123A PC1 (PLG9–A2) TO S6 (6)
0124A S6 (7) TO PC1 (PLG9–D3)
0125A PC1 (PLG8–F1) TO PLG6 (1)
0126A PC1 (PLG8–F2) TO PLG6 (2)
0127A S5 (TOP) TO PC1 (PLG9–B3)
0128A S5 (CENTER) TO PC1 (PLG9–D2)
0129A S5 (BOTTOM) TO PC1 (PLG9–2)
0134A R1 (PLG10–1) TO PC1 (PLG9–D1)
0135A R1 (PLG10–2) TO PC1 (PLG9–C1)
0136A R1 (PLG10–3) TO PC1 (PLG9–A3)
0137A SR1 (AC) TO F1
0138A RC3 (1) TO F2
0138B PC1 (PLG8–A3) TO PLG3 (1)
0139A PC1 (PLG8–C3) TO PC8 (PLG13–1)
0140A PC1 (PLG8–D2) TO PC8 (PLG13–5)
0141A PC1 (PLG8–D3) TO PC8 (PLG13–6)
0142A PC1 (PLG8–K2) TO PC8 (PLG13–7)
0143A PC1 (PLG8–J2) TO PC8 (PLG13–9)
0144A PC1 (PLG8–B3) TO PC8 (PLG13–10)
TM-4412 Page 61D502K 5+4
13-1. Wetstacking
1
SECTION 13 – RUN-IN PROCEDURE
Y Do not perform run-in
procedure at less than 20
volts weld output and do n ot
exceed duty cycle or equipment damage may occur.
1 Welding Generator
2
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
. Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
run_in1 8/01
TM-4412 Page 62 D502K 5+4
13-2. Run-In Procedure Using Load Bank
4
2
3
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
Y Do not perform run-in
procedure at less than 20
1
volts weld output and do n ot
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
. Check oil level frequently dur-
ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Y Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
TM-4412 Page 63D502K 5+4
13-3. Run-In Procedure Using Resistance Grid
6
2
3
4
+
5
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
Y Do not perform run-in
procedure at less than 20
volts weld output and do n ot
exceed duty cycle or equipment damage may occur.
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rating label, or the specifications section in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
. Check oil level frequently dur-
ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Y Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
TM-4412 Page 64 D502K 5+4
S-0684
TM-4412 March 2002
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
Eff w/LC110463 And Following
For OM-4412 (206 995)
SECTION 14 – PARTS LIST FOR LC110463 AND FOLLOWING
. Hardware is common and
not available unless listed.
14
2
5
4 6
7
13
18
12
11
9
8
10
112
12
103
1
3
111
110
109 (Fig. 14-5)
104
19
16
17
15
82
102
93
92
94
83
85
84
86
87
88
89
90
91
95
96
108
106
107 (FIG. 14-3)
TM-4412 Page 66 D502K 5+4
101 (FIG. 14-2)
100
105
Figure 14-1. Main Assembly
91
97
98
99
Eff w/LC110463 And Following
20
21
22
23
24
25
28
81
26
75
77
76
27
29
78
80
31
79
30
33
32
34
35
45
36
38
37
41
42
39
44
43
40
30
31
73
74
71
72 (Fig 14-4)
70
62
61
66
67
68
69
63
60
64
65
59
55
58
57
56
46
49
48
47
50
57
51
53
52
54
803 201
TM-4412 Page 67D502K 5+4
Eff w/LC110463 And Following
Item
No.
1 +199294 Panel, Gen Lh Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 +199301 Panel, Engine Side Stainless Stl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Z1 202647 Reactor, AC Environmental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 1T 038621 Block, Term 30 Amp 4 Pole Frict Term Str Both Side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 038620 Link, Jumper Term Blk 30 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 081499 Bracket, Mtg Terminal Strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 206352 Brace, Front To Center Upright 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 SR4, SR5 035704 Rectifier, Integ Bridge 40 Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 CB4 045061 Circuit Breaker, Auto Reset 24vdc 7 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 201697 Pan, Reactor & rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 T1 205636 Transformer, W/Brkt Environmental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 173352 Extrusion, Rubber Clamp/Bulb 2.75 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 189708 Firewall, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 200968 Hose, Elbow Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 206393 Pipe, Air Cleaner Intake Kubota V3300 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 189763 Bracket, Mtg Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 189764 Air Cleaner, Intake (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 189464 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 206351 Upright, Center Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 +206541 Cover, Top Stainless Steel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 189052 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 190198 Cap, Tank Screw–on 3.500 In W/Vent W/Lanyard (included w/tank) 1. . . . . . . . . . . . . . . . . . . . . . .
23 176103 Label, Use Diesel Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 176104 Label, Warning Falling Equipment Can Cause Serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 176230 Label, Hot Exhaust Parts Do Not Touch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 105734 Pipe, Muffler Extension Elbow 1.750 Od 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 202629 Cover, Radiator Access Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 202633 Support, Cover E–coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 010875 Clamp, Muffler 2.000 Dia U Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 176106 Label, Warning Moving Parts Can Cause Serious 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 206388 Guard, Fan (Left) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 206517 Radiator, W/Shroud & 7# Cap 4row Core Assy Rda (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . .
33 207192 Panel, Engine Extension L.h. Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 207005 Grill, Rear Panel Stainless Kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 207188 Upright, Rear Radiator Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 190206 Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 108081 Terminal Protector, Battery Post Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 203430 Bracket, Battery Holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 BATT 190896 Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Low Mainte (Dry) 1. . . . . . . . . . . . . . . . . . . . . . . .
41 201006 Bolt, J Stl .312–18 X 7.750 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 +202639 Cover, Battery Access Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 176108 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 207193 Panel, Engine Extension R.h. Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 206387 Guard, Fan (Right) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 190992 Keeper, Latch Engine Access Door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 206604 Channel, Stiffener Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 190126 Latch, Paddle Series 20 (Ss) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 206999 Label, Maintenance D502k 5+4 Kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 199338 Door, Engine Access Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Figure 14-1. Main Assembly
192938 Filter, Air Element Primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦192939 Filter, Air Element Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206518 Radiator, Big Blue Air Pak 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605982 Cap, Radiator Pressure 7 Lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206384 Shroud, Radiator Kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-4412 Page 68 D502K 5+4
Eff w/LC110463 And Following
Item
No.
51 189975 Hinge, Door Access 180 Deg. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 087341 Stop, Door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 190190 Tank, Coolant Recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 199298 Panel, Rocker Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 199300 Panel, Gen Rh Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 206391 Hose, Radiator Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 165271 Valve, Oil Drain 3/8–18 Nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 176529 Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59 113854 Hose, Sae .500 Id X .780 Od Xcoil 1.666. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 176528 Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61 206906 Adapter, Oil Drain Fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 Washer, Oil Drain (Available Through Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63 199849 Screw, 625–11x4.00 Hex Hd–pln Gr5 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64 071731 Washer, Flat .656idx2.250odx.187t Stl Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65 206396 Bracket, Mtg Engine Kubota V3300 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66 071890 Retainer, Mount Eng/Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67 071730 Tubing, Stl .875 Od X12ga Wall X 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68 083476 Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69 135205 Nut, 625–11 .94hex .77h Stl Pld Elastic Stop Nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70 *207717 Filter, Oil (Spin-On Cartridge Type) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 *207715 Filter, Fuel Secondary (Spin–on, Cartrige Type) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72 Figure 14-4 Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73 206399 Engine, Kubota Dsl Elec V3300 (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74 198990 Adapter, Oil Pressure Sender 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75 S12 187542 Switch, Pressure Oil 11psi No Cont Frict Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
77 *207712 Belt, Fan 13 X 1200mm V–belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 206390 Hose, Radiator Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79 206392 Hose, Air Cleaner Intake Kubota V3300 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80 207719 Fan, Engine Cooling 430mm, 6 Blade Pusher 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81 206383 Manifold, Exhaust Muffler Kubota V3300 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82 189245 Tank, Fuel 23.0 Gal (includes fuel cap) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83 124253 Bushing, Tank Fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 189912 Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85 189909 Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 189913 Ftg, Stl Barbed Elbow Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87 190142 Sender, Fuel Gauge 9.750 Deep Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88 189910 Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89 189908 Valve, Drain Fuel 180 Deg Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 181572 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91 191446 Extrusion, Rubber W/Adhesive 1.000 X 1.000 ”d” 4.6 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 FUEL PUMP 207721 Pump, Fuel Electric 12vdc 1.5a 400 Cc/Min 5psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93 *207714 Filter, Fuel Pre (In–line) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94 +206350 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95 196220 Bracket, Holddown Fuel Tank Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96 192362 Bracket, Mtg Nyl 1/2 Conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97 191897 Bracket, Mtg Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98 200864 Label, Do Not Weld On Base Ce 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 206998 Label, Manufacturing Rating D502k 5+4 Kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
TEMP SNDR 193231 Sender, Coolant Temp 300 Deg F 1/2–14 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part
No.
Figure 14-1. Main Assembly (Continued)
191626 Bumper, Door Engine Access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199507 Hose Assy, Oil Drain 20”lg (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206380 Adapter, Engine Kubota V3300 (See Figure 14-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206907 Plug Assy, W/Leads Elec Kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*207713 Thermostat, 170f (76.5c) W/Gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206379 Flywheel, Kubota V3300 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207722 Gasket, Exhaust Manifold Metal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107816 Hose, Sae .250 Id X .500 Od Xcoil 4.1 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
TM-4412 Page 69D502K 5+4
Quantity
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
100 R3 189699 Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101 Figure 14-2 Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 191512 Bracket, Holddown Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103 189731 Firewall, Bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 199305 Cover, Top Front Upright Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105 202637 Upright, Front Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106 200910 Label, Warning Electric Shock And Moving Parts CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107 Figure 14-3 Panel, Front w/Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 ♦ Transformer, Current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109 SR3 Figure 14-5 Main Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 193453 Bracket, Mtg Box Fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111 PC1 207397 Module, Field Current Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112 203260 Label, Caution Do Not Use Ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191819 Hose, Sae .312 Id X .560 Od X 14.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
095636 Hose, Sae .187 Id X .410 Od X 30.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
198584 Hose, Sae .312 Id X .560 Od X 4.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
049525 Nut, 312–18 U–nut Multi–thread 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
190058 Nut, 250–20 U–nut Multi–thread 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206993 Kit, Label (Includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206 993.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
4
13
15
12
16
5
3
2
1
10
11
8
9
14
TM-4412 Page 70 D502K 5+4
7
6
Figure 14-2. Control Box Assembly
803 203
Eff w/LC110463 And Following
Item
No.
1 F1, F2 085874 Fuse, Mintr Cer Slo–blo 10. Amp 250 Volt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 201077 Control Box, Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 201078 Control Box, Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 201079 Cover, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 134201 Stand–off Support, Pc Card .312/.375w/Post&lock .43 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 PC9 192224 Circuit Card Assy, Display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 C9 087110 Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 177136 Clamp, Capacitor 1.375 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11 SR1 035704 Rectifier, Integ Bridge 40. Amp 800v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 CR1, CR5 090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
13 CR2 173069 Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 T 207139 Timer, Delay On Make/Break Open 3–60 Sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 CB10 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 D8/C8 189701 Diode/Capacitor Board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Mkgs.
CB11, CB12 139266 Circuit Breaker, Man Reset 1p 15a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RC3 158466 Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RC1 135133 Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S7 199691 Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (located on . . . . . . . . . . . . . . . . . . . .
PLG10 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D9/C9
D10/C10
Part
No.
Figure 14-2. Control Box Assembly (Figure 14-1 Item 101)
206736 Harness, Control Box,Weld Control L.h. (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206398 Harness, Engine Kubota V3300 (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
front panel, see Figure 14-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148850 Socket, Relay 5 Pin 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-4412 Page 71D502K 5+4
. Hardware is common and
not available unless listed.
1
Eff w/LC110463 And Following
3
2
4
5
6
8
9
7
42
41
43
40
39
38
44
45
37
36
35
33
34
30
32
31
33
20
21
22
18
19
10
11
12
13
14
15
16
17
29
Item
No.
Dia.
Mkgs.
Part
No.
Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 107)
1 206212 Plate, Screened Ident Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 206382 Panel, Engine/Weld Control Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 S3 208278 Switch, Range/Changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192558 Harness, Range Switch (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RC6 148389 Conn,Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 R1 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-4412 Page 72 D502K 5+4
28
26 25
27
Figure 14-3. Panel, Front w/Components
Description
24
23
803 202
Quantity
Eff w/LC110463 And Following
Item
No.
5 S6 193234 Switch, Rotary 6 Position Gold Contacts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 S5 011609 Switch, Tgl Spdt 15a 125vac On–none–on Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 CB5 139266 Circuit Breaker, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 202209 Spacer, Nylon 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 PC6 192995 Circuit Card Assy, Connector/Receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 S1 207720 Switch, Ignition 3 Position (Mom–off–mom) W/Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 S7 199691 Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (included in . . . . . . . . . . . . . . .
12 CB1 201083 Circuit Breaker, Man Reset 2p 20a 250vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 CB2 093996 Circuit Breaker, Man Reset 1p 20a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 GFCI-1 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5–20r Gfi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 RC1 147632 Rcpt, Tw Lk Grd 2p3w 30a 250v *L6–30r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 200910 Label, Warning Electric Shock And Moving Parts CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 +202641 Panel, Auxiliary Power Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 601836 Nut, 250–20 .50hex .19h Brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 083030 Stud, Brs .250–20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 ♦196073 Label, Do Not Switch While Welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 ♦ Switch, Polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 199303 Panel, Mtg Terminal Power Output Stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 PC4, PC5 189744 Circuit Card Assy, Filter Hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 NEGATIVE 039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 134201 Stand–off Support, Pc Card .312/.375w/Post&lock .43 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 181169 Spacer, Output Stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 186621 Boot, Generic Output Stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 ♦ Handle, Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 ♦ Pin, Spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 POSITIVE 039047 Terminal, Pwr Output Red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 193260 Cover, Receptacle 2.250 Dia. Lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 193258 Cover, Receptacle Gfci Lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 190323 Boot, Circuit Breaker Clear Hex Nut 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 021385 Boot, Toggle Switch Lever 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 FUEL 192265 Gauge, Fuel Elec Switch W/O Switchgage Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 HM 118058 Meter, Hour 12–24vdc 2.25 Dia High Profile Stainles 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 AM 118060 Meter, Amp Dc 60–0–60 2.250 Dia High Profile Stainl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 TEMP 193229 Gauge, Coolant Temp 0– 300 Deg F Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 ♦ Meter, Weld Amps 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 ♦ Meter, Weld Volts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 189161 Handle, Switch Range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 010647 Pin, Spring Cs .156 X 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 097924 Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
PLG9 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG14 141450 Conn, Rect Metrmate 10skt 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RC10 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB13 139266 Circuit Breaker, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part
No.
Figure 14-3. Panel, Front w/Components (Continued)
206809 Harness, Weld Control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196603 Seal, Switch 6 Position Rotary .250 Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
164617 Clip, Wiring Straight 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
engine harness, see Figure 14-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201553 Clip, Retaining Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201109 Harness, Receptacle Auxillary Power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010146 Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
TM-4412 Page 73D502K 5+4
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Continued)
193158 Harness, Unit Weld Control – CV (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG6 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG8 193184 Conn, Rect Cinch 30 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG13 147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG3 158465 Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
088731 Bushing, Snap–in Nyl .375 Id X .500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135873 Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
187654 Seal, Wire Univ 12p/S 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196602 Plug, Cavity 18, 30 Position Cinch Connector 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
024103 Blank, Snap–in Nyl .750 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120304 Blank, Snap–in Nyl .250 Mtg Hole Black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206 993.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
not available unless listed.
20
17
19
13
16
15
14
12
9
10
11
8
7
6
5
3
4
2
32
1
34
29
35
33
31
30
28
29
26
27
25
18
18
21
22
23
24
803 204-A
TM-4412 Page 74 D502K 5+4
Figure 14-4. Generator
Eff w/LC110463 And Following
Item
No.
1 132053 Screw, 375-16 X 1.50hexhd Pln Gr 5pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 183387 Washer, Conical Spring .406 Id X .875 Od Pltd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 195911 Endbell, Gen (Consisting Of) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 143220 O-ring, 2.859 Id X .139cs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6 WELD STAT OR +208287 Stator, Weld Assembly Complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 013367 Label, Warning Moving Parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 190197 Guard, Generator Wire Mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 172674 Spring, Ext .240 Od X .041 Wire X 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 191580 Cover, Starter Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 208216 Spacer, Stl Kubota V3300 18ga Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 039207 Baffle, Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 REV FLD 202452 Rotor, Gen (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 024617 Ring, Rtng Ext 1.375 Shaft X .050thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 195547 Fan, Rotor Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 049026 Screw, M10-1.5 X 25hexhd Pln 8.8pln 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 083883 Washer, Lock .042 Id X 0.709 Od 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 202302 Plate, Flex 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 206380 Adapter, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 605231 Screw, M10-1.5 X 35hexhd Pln 8.8pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 194512 Washer, Flat 1.250 Od X .406 Id X 7 Ga Thk Stal Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 183387 Washer, Cone .380 Id X .860od X .109t Stl Pld 4000lbs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 198631 Nut, M10 Hex Lock Nut Stl Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 191579 Cover, Starter Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 172555 Screw, M10-1.5 X 50hexhd Pln 8.8pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 602159 Screw, .312-18 X .75hexwhd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 604950 Screw, .312-18 X 2.25hexhd Pln Gr 5pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 602211 Washer, Lock .318 Id X 0.586 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 139341 Washer, Exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 *190823 Brush, Contact 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 188560 Clip, Spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 189142 Brushholder Assembly, Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 602242 Washer, Flat .375idx0.875odx.083t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 604534 Screw, 312–18x1.25 Hex Hd–pln Gr5 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
AUX STATOR 201099 Stator, Exciter/Aux Pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1 168071 Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Part
No.
Figure 14-4. Generator (Figure 14-1 Item 72)
190259 Harness, Brush (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
187651 Seal, Wire Univ 9p/S 3 Row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Quantity
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206 993.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4412 Page 75D502K 5+4
. Hardware is common and
not available unless listed.
2
1
Eff w/LC110463 And Following
4
3
5
6
7
8
9
802 279-A
Figure 14-5. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-5. Main Rectifier Assembly (Figure 14-1 Item 109)
SR3 208279 RECTIFIER, environmental (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 188137 CONNECTION BOARD, rectifier AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 188517 BUS BAR, connection board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 188135 ENCLOSURE, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 134201 STAND-OFF, support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC3 201449 CIRCUIT CARD ASSEMBLY, protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 188136 INSULATOR, heat sink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 188493 HEAT SINK, rectifier al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 D3, D5, D7 208334 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 D2, D4, D6 208335 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Base Group
TM-4412 Page 76 D502K 5+4
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA 1/02
File a claim for loss or damage during
shipment.
Loading...