null  null
TM-4412
March 2002
Eff. w/Serial Number LC110463
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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
5
6
6
7
7
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator (See Section 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
9
9
10
11
12
13
14
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.
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
17
18
19
CALIFORNIA
Proposition 65
Warning
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Inspecting/Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
22
24
25
26
27
28
29
SECTION 8 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
SECTION 9 – EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
SECTION 10 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . .
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . .
10-4. Waveforms For Section 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9 . . . . . . . . . . . . . . . . . . . .
10-8. Using Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. LED Board PC9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10.Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12.Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
40
42
43
44
45
46
47
48
49
50
51
(Continued)
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
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause cancer,
birth defects, and other
reproductive harm.
TABLE OF CONTENTS
SECTION 11 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
52
53
SECTION 12 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
SECTION 13 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
62
63
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.
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.
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.
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.
Y Only qualified persons should test, maintain, and repair this
unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
ENGINE EXHAUST GASES can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit unless the procedure specifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insulating 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.
D Do not breathe exhaust fumes.
D Use in open, well-ventilated areas, or vent exhaust outside and away from any building air intakes.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
D
D
D
D
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.
Keep hands, hair, loose clothing, and tools away from moving parts.
Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator components.
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.
D502K 5+4
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 connecting battery cables.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
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 1
STEAM AND HOT COOLANT can burn.
TILTING OR TIPPING can cause injury.
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 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.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
H.F. RADIATION can cause interference.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
D
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 equipment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
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.
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.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
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.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
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 powerfrequency 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:
2. Arrange cables to one side and away from the operator.
TM-4412 Page 2
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.
D502K 5+4
SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
A
3
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Time
Hours
Seconds
Amperes
Three Phase
Electrode
Connection
V
h
s
Read Operator’s
Manual
Circuit Breaker
Work Connection
Engine-Driven,
Three-Phase
Alternator With
Rectifier
G
1
Single Phase
Do Not Switch
While Welding
Hz
Hertz
Contactor On
D502K 5+4
TM-4412 Page 3
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld
Output
Range
Rated Welding
Output
Maximum
Open-Circuit
Voltage
CC/DC
20 – 600 A
500 A, 40 Volts DC,
100% Duty Cycle
95
14 – 40 V
600 A, 44 Volts DC,
40% Duty Cycle
56
CV/DC
Auxiliary Power Rating
Engine
Fuel
Capacity
Standard:
Single-Phase,
4 kVA/kW, 20/17 A,
120/240 V AC, 50/60 Hz
Kubota V3300-B
Water-Cooled, Four
Cylinder, 49 HP Diesel
Engine
25 gal
(95 L)
3-2. Dimensions, Weights, And Operating Angles
Dimensions
G
50 in (1270 mm)
(to top of muffler)
Height
28-1/2 in (724 mm)
(mtg. brackets turned in)
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
Width
30-3/4 in (781 mm)
(mtg. brackets turned out)
Depth
69-1/2 in (1765 mm)
A
69-1/2 in (1765 mm)
B*
55-7/8 in (1419 mm)
C*
46-3/8 in (1178)
D*
9-1/2 in (241 mm)
E
27-1/2 in (699 mm)
F
1 in (25 mm)
G
29-1/2 in (749 mm)
9/16 in (14 mm) Dia.
4 Holes
H
* With mounting brackets in center
position. Dimensions vary with location of mounting brackets.
Weight
No fuel: 1808 lb (820 kg)
TM-4412 Page 4
Y Do not move or operate unit where it could
tip.
A
B
C
30°
H
D
20°
30°
20°
Front Panel End
F
E
802 161-A
803 122
D502K 5+4
3-3. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
Ranges
300 – Max
185 – 525
125 – 400
85 – 250
55 – 125
DC VOLTS
80
60
40
20
0
0
100
200
300
400 500 600
DC AMPERES
700
800
900 1000
400 500 600
DC AMPERES
700
800
900 1000
B. MIG Mode
100
DC VOLTS
80
60
MAX
40
MIN
20
0
0
100
200
300
C. TIG Mode
100
Ranges
60–450
40–330
30–220
20–110
DC VOLTS
80
60
40
20
0
0
100
200
300
400
DC AMPERES
500
600
700
208 135 / 203 415 / 208 136
D502K 5+4
TM-4412 Page 5
3-4. Fuel Consumption
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.
LITERS/HR.
The curve shows typical fuel use
under weld or power loads.
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
DC WELD AMPERES AT 100% DUTY CYCLE
700
208 137
3-5. Duty Cycle And Overheating
100% Duty Cycle At 500 Amperes
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
202 356
TM-4412 Page 6
D502K 5+4
3-6. AC Auxiliary Power Curve
The ac power curve shows the auxiliary power in amperes available at
the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
5
10
15
20
AC AMPERES IN 240V MODE
25
30
0
10
20
30
40
AC AMPERES IN 120V MODE
50
60
193 018
3-7. Manufacturer’s Rating Label
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
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Y Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Grounding
3
1
4
GND/PE
Y Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
2
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
1
2
3
4
2
Generator Base
Metal Vehicle Frame
Equipment Grounding Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
install2 1/01– Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
4-2. Installing Exhaust Pipe
Y Stop engine and let cool.
. Point
exhaust pipe in desired direction but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
TM-4412 Page 8
803 122 / Ref. 802 169 / Ref. 202 705
D502K 5+4
4-3. Mounting Welding Generator
Y Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
1
1
2
3
Mounting Bracket
1/2 in Bolt And Washer
(Minimum – Not Supplied)
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.
Welding Unit In Place
To Bolt Unit In Place:
Bolting Unit In Place
2
1
Remove hardware securing the
four mounting brackets to 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).
3
Tools Needed:
9/16 in
803 122 / Ref. 802 169-B
4-4. Connecting The Battery
. Reinstall cover after connecting battery.
Y Connect Negative (–) Cable Last.
+
–
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
Remove air bleed screw
when filling radiator.
See Section 4-6.
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Capacity: w/Overflow
Tank 10 qt (9.5 L)
Diesel
Full
Coolant Recovery
Tank
Full
803 123-A
. Check all engine fluids daily.
tions). Leave filler neck empty to allow room
for expansion.
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.
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.
. 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 specificaTM-4412 Page 10
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 of 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 this engine. Do not use 100% antifreeze 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.
. To 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).
D502K 5+4
4-6. Adding Coolant To Radiator
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. Do not use 100% antifreeze
or severe damage will occur.
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
1
1 Radiator Air Bleed Screw
2 Radiator Cap
Remove air bleed screw. Add coolant 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 Section 4-5).
2
Tools Needed:
3/8 in
Full
Capacity: w/Overflow
Tank 10 qt (9.5 L)
803 123-A / 206 580
D502K 5+4
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 holder cable to Positive (+) terminal on
left and work cable to Negative (–) terminal
on right.
For Direct Current Electrode Negative
TM-4412 Page 12
(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.
D502K 5+4
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Y Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 100%
Duty
Cycle
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)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
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)
700
4/0 (120)
2 ea. 2/0
(2x70)
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)
4 ea. 4/0
(4x120)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
10 – 100% Duty Cycle
* 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.
D502K 5+4
TM-4412 Page 13
4-9. Connecting To Remote 14 Receptacle RC14
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.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
OR
I
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB13.
J
Contact closure to I completes
115 volt ac contactor control
circuit.
K
Chassis common.
G
Circuit common for 24 and 115
volt ac circuit.
115 VOLTS AC
803 122
GND
NEUTRAL
*The remaining sockets are not used.
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)
8
9
12
13
5 6
4
3
2
7
10
1
11
206 212-A / 803 122
TM-4412 Page 16
D502K 5+4
5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls
4
1
Use gauge to check fuel level when engine is
running.
Start/Preheat Switch
Use switch to start engine and operate glow
plug for cold weather starting.
Engine runs
continuously.
at
weld/power
speed
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
5
Fuel Gauge
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 until 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).
7
Process/Contactor Control Switch
See Section 5-3 for Process/Contactor Control switch information.
8
Amperage Range Switch
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)
Use switch to select weld amperage range.
Y Do not switch under load.
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 switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
Engine Gauges
9
D502K 5+4
. The numbers around the control are for
Y Do not switch under load.
Use meter to monitor engine running time for
scheduling maintenance.
with engine off, turn Start/
Preheat switch to Preheat position.
Weld output would be about 263 A DC with
controls set as shown (50% of 125 to 400 A).
Weld Controls
For most welding applications, use lowest amperage range possible to help prevent arc outages.
. To read gauges
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.
Voltage/Amperage Adjust Control
With Process/Contactor Control switch in any
Stick or TIG setting, use control to adjust am-
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.
TM-4412 Page 17
5-3. Process/Contactor Control Switch
1
206 212-A
1
Process/Contactor Control Switch
(See Section 5-1 For Location)
Section 5-4).
Y Weld output terminals are energized
when Process/Contactor Control
switch is in 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
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 Terminals 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
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14 Receptacle
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
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot
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
Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 4-9).
1
Example: Combination Remote Amperage Control (Stick) With Remote On/Off Control
In Example:
Process = Stick (Using Remote On/Off)
Range = 125 to 400 A DC
Min = 125 A DC
Max = 400 A DC
Max (400 A DC)
Min (125 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
Example: Combination Remote Amperage Control (TIG) With Remote On/Off Control
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)
Max (185 A DC)
Min (40 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 192 895-A / 802 311-A
D502K 5+4
TM-4412 Page 19
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. 120 Volt And 240 Volt Receptacles
. Auxiliary power is not affected
by weld output.
1
3
2
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 30 A AC Twistlock
Receptacle RC1
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, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
4
3
Circuit Breaker CB1
4
Circuit Breaker CB2
CB1 protects RC1 and the generator 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
191 624
TM-4412 Page 20
D502K 5+4
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
Y Stop engine before maintaining.
Recycle
engine
fluids.
. See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8h
Coolant
Full
Wipe Up
Spills.
OIL
Full
Check Fluid
Levels. See
Section 4-5.
50 h
Clean And
Tighten Weld
Terminals.
Check Fuel Lines
And Connections.
100 h
Check Air Cleaner
Hoses For Cracks
And Loose Clamps.
Clean Air Filter.
See Section 7-3.
1/2 in.
(13 mm)
Check
Belt
Tension.
Clean And
Tighten
Battery
Connections.
200 h
Change Oil Filter.
See Section 7-6.
Service More Often
In Dirty Conditions.
Change Oil. See
Section 7-6.
Check
Radiator
Hoses And
Clamps.
250 h
Replace
Unreadable
Labels.
TM-4412 Page 22
D502K 5+4
500 h
Replace Fan Belt.
Air Hose
Check And
Clean Spark
Arrestor. See
Section 7-4.
Clean Radiator
Exterior.
Repair Or
Replace
Cracked
Cables.
800 h
Replace Primary
Fuel Filter. See
Section 7-6.
Replace Secondary Fuel
Filter. See Section 7-6.
Check Valve
Clearance.*
1000 h
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
Drain Sludge
From Fuel
Tank. See
Section 7-6.
FUEL
SLUDGE
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
OR
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
Y Stop engine.
1
2
3
Y Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
. 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
damage when determining whether
to clean or replace the primary element.
Optional
5
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). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
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 it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B
TM-4412 Page 24
D502K 5+4
7-4. Inspecting/Cleaning Optional Spark Arrestor
Y Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
3
1
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.
2
Tools Needed:
3/8 in
Ref. 206 212-A / 803 122
Notes
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 meter (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)
2
1
3
Tools Needed:
803 123-A
TM-4412 Page 26
D502K 5+4
7-6. Servicing Fuel And Lubrication Systems
Tools Needed:
4
5
3
Right Side
1
6
2
Ref. 800 159-E / Ref. 802 170 / 803 123-A
Y Stop engine and let cool.
To drain water from fuel system:
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)
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
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
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.
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
Y Stop engine and let cool.
1
Radiator Cap
2
RAdiator Air Bleed Screw
3
Radiator Drain Cock
Drain engine coolant according to
procedure in engine manual.
2
Add engine coolant according to
procedure in Section 4-6.
Tools Needed:
3/8 in
1
3
Ref. 803 123-A / 803 136
TM-4412 Page 28
D502K 5+4
7-8. Overload Protection
Y Stop engine.
1
2
Fuse F1
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.
2
7
6
4
8
1
3
4
Circuit Breaker CB4 (Not Shown)
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 output to RC14 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 to 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.
803 123-A / 802 170-D / Ref. 802 313
D502K 5+4
TM-4412 Page 29
SECTION 8 – THEORY OF OPERATION
11
10
Filter Board
PC6/Remote
Receptacle RC14
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.
Circuit
Breakers
CB5, CB13
LED Board PC9
12
13
Voltage/
Amperage
Adjust Control
Switch S5
Process/
Contactor Switch S6
Remote Electrode
Hot
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 stator windings.
Voltage/
Amperage
Adjust
Control R1
5 Fuses F1, F2
Protect aux. stator (exciter) windings
from overload.
Field
Current
Regulator
Board
PC1
2
Control Relay
CR5
2
Voltage/Amperage Adjust
Control R1
Adjusts voltage/amperage within
range selected by S3.
6
7
Field Current Regulator Board
PC1
Adjust weld output by changing revolving filed current after comparing
feedback to voltage/amperage setting of R1.
8
7
4 Stator Windings
Supply power to exciter, auxiliary
power, and weld circuits.
6 Integrated Rectifier SR1
Changes ac output of stator windings
to dc to supply excitation current to
the exciter revolving field.
9
Control Relay
CR2
5
Integrated
Rectifier
SR1
8
1
Fuse F2
Fuse F1
4
3
Engine
5
Revolving
Fields
(Rotor)
Exciter
Stator Windings
Weld
1 Engine
Supplies force to turn revolving
fields.
Auxiliary Power
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.
24
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.
Transformer
T1
12 Process/Contactor Control
Switch S6
Selects weld process and weld output on/off control (Weld Terminals Always On or Weld Terminals Remotely Controlled).
25
Integrated
Rectifiers
SR4, SR5
Figure 10-1. Functional Diagram
TM-4412 Page 30
D502K 5+4
AC Or DC Control Circuits
14 HF Filter Boards PC4, PC5
Protect unit from high frequency.
3φ Power
15 Circuit Breakers CB1 And CB2
Protect AC receptacles RC1 and
GFCI1 from overload.
Weld Current Circuit
Either Mechanical Coupling
Or External Circuits
Magnetic Coupling
♦
13 Voltage/Amperage Adjust Control
Switch S5
Selects Panel or Remote voltage/amperage control.
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.
Optional
18 Amperage Range Switch S3
Selects coarse range of weld output
from Z1.
19 Main Rectifier SR3
Changes ac weld output to dc.
OCV
Feedback
22♦
22 ♦
Voltmeter
V1
17
20 HF Filter Board PC3
Protects main rectifier from high frequency and voltage spikes, and provides OCV feedback signal to PC1.
18
22 Voltmeter V1, Ammeter A1
Display weld voltage and current.
19
Amperage
Range
Switch S3
Reactor
Z1
21 Polarity/AC Selector Switch S13
Selects ac weld output or polarity of dc
weld output.
Ammeter
A2
Main
Rectifier
SR3
20
HF Filter
Board PC3
21♦
Polarity/AC
Selector
Switch S13
16
14
HF Filter
Board PC4
14
14
HF Filter
Board PC4
AC
Receptacles
RC1, GFCI1
23
D502K 5+4
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.
15
Circuit Breakers
CB1, CB2
23 Electrode And Work Weld Output
Terminals
Provide weld output. Without optional
Polarity/AC Selector switch S13 terminals are labeled negative (–) and positive (+).
HF Filter
Board PC5
23
Electrode
Weld Output
Terminal
Work
Weld Output
Terminal
Electrode
Work
TM-4412 Page 31
SECTION 9 – EXPLANATION OF ELECTRICAL PARTS
elect_parts 1/01
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
PART NAME
CAPACITOR
FUNCTION
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.
PICTURE
CIRCUIT SYMBOL
POLARIZED
C1
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
FUSE
HALL DEVICE
RESISTOR
POTENTIOMETER
OR
RHEOSTAT
TM-4412 Page 32
NON-POL.
C1
CB1
A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
D1
A protection device, usually an enclosed
piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
F1
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.
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.
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.
HD1
FIXED
R1
FIXED TAPPED
R1
VARIABLE
R1
D502K 5+4
PART NAME
FAN MOTOR
FUNCTION
PICTURE
CIRCUIT SYMBOL
This device provides cooling of the internal
parts of a welding power source.
FM
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)
These are electromechanical devices used to
start or stop the flow of shielding gas or
water.
RELAY––COIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
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.
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
CONTACTOR
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.
A heavy duty relay. Usually used to make
and break the welding arc or primary power.
VR1
GS1
OR
WS1
COIL
CR1
CR1
NRM OPEN NRM CLOSED
POINTS
POINTS
TP1
TP1
NRM OPEN NRM CLOSED
COIL
W
W
NRM OPEN
POINTS
PILOT LIGHT
STABILIZER/
REACTOR
D502K 5+4
A light located on the front panel which
indicates if the machine is on or off.
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.
1
PL
Z1
L1
TM-4412 Page 33
PART NAME
MOTOR
FUNCTION
PICTURE
CIRCUIT SYMBOL
A device that is typically used to feed wire in
a MIG welding system.
B1
SHUNT
MOSFET
IGBT
BRUSHES/SLIP
RINGS
A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
SHUNT
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.
D
G
AS
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.
Components that allow electrical connections
between stationary and rotating contacts.
S
C1
G1 (B1)
E1
SLIP
RINGS
BRUSHES
TERMINAL STRIP
SWITCH
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.)
A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
1T
42 42 104 105 74
A
B
SPST
DPST
TM-4412 Page 34
C
D
E
SPDT
DPDT
D502K 5+4
PART NAME
SCR
THERMISTOR
TRANSFORMER
FUNCTION
PICTURE
CIRCUIT SYMBOL
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.
K
G
A
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.
RT1
OR
TH1
A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
T1
INTEGRATED
BRIDGE
RECTIFIER
An arrangement of four diodes used to
change AC to DC.
–
SPARK GAP
CURRENT
TRANSFORMER
D502K 5+4
+
AC
AC
+
AC
_
AC
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.
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.
G
CT1
OR
CT1
TM-4412 Page 35
SECTION 10 – TROUBLESHOOTING
10-1. Troubleshooting Tables
. See Section 10-2 for test points and
values and Section 14 and following
for parts location.
A. Welding
Trouble
Remedy
No weld output; auxiliary power output Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Weld
okay.
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 necessary.
No weld output or auxiliary power 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).
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
High weld output.
Remedy
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 Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 7-8).
frequently during low voltage (short arc
length) conditions.
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.
Low weld output.
Check engine speed, and adjust if necessary (see Section 7-5).
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 necessary.
Low open-circuit voltage.
Check engine speed, and adjust if necessary (see Section 7-5).
No remote fine amperage or voltage Place Voltage/Amperage Adjust Control switch S5 in Weld Terminals Remotely Controlled position.
control.
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 Reset circuit breaker CB5 or CB6 (see Section 7-8).
generator.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Repair or replace wire feeder.
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.
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. Feedback 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 Reset receptacle circuit breakers.
okay.
Check resistance of auxiliary power windings between leads 81 and 84. Replace exciter stator (aux. stator) if necessary.
D502K 5+4
TM-4412 Page 37
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
receptacles.
at
auxiliary
power 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).
Low output
receptacles.
at
auxiliary
power 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
Engine will not crank.
Remedy
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/Pre- Check coolant level. Automatic shutdown system stops engine if engine temperature is too high (see Secheat switch S1 is released.
tions 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.
Engine hard to start in cold weather.
Turn Start/Preheat switch S1 to Preheat position before starting (see Section or 5-1).
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).
Engine suddenly stops.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low (see Sections 4-5).
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.
Engine slowly stopped and cannot be
restarted.
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; Dry engine (see Section 13).
wetstacking occurs.
D502K 5+4
TM-4412 Page 39
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
V3, R3
V1, R1
V2, R2
V4, R4
Adjust R3
according to
Section 10-12
V8, R7
V9, R8
See Section
10-5 for
PC6 data
V7
V5, R5
I2
V18
V19
See Section
4-9 for RC14
information
I1
V6, R6
V17
V20
V21
V14,
R12
V16
Timer
Relay T
TM-4412 Page 40
V15
R13
D502K 5+4
V23
V22
See Section 8 for
PC3 information
V24
V12, R11
V10,
R9
V13,
Waveforms
A and B
V11, R10
See
Section 10-4
for waveforms
See Section 8
for PC4, PC5
information
Engine oil pressure
latching
relay CR1
Engine temp.
latching relay
CR2
PC1 power
supply relay
CR5
206 628-A
D502K 5+4
TM-4412 Page 41
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)
Test Equipment Needed:
Voltage Readings
a)
Tolerance – ±10% unless specified
b)
Condition – 70°F (21°C); cold
machine (no warm-up); no load
Reference – single arrow: reference
to circuit common (lead 42); double
arrow: reference to points indicated
Process/Contactor Control switch S6
in Weld Terminals Always On – CC
Stick position unless noted
Wiring Connections – see Section 12
c)
d)
e)
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.)
Resistance Values
unless
Tolerance
specified
b)
Condition – 70°F (21°C); cold
machine (no warm-up)
c)
Wiring Connections
Section 12
d)
Stop engine before checking
resistance
R1 thru R6
R7
R8
R9 thru R11
R12
R13
–
±10%
a)
– see
Less than 1 ohm
18.5 ohms
14.2 ohms
Less than 1 ohm
15 ohms
Less than 1 ohm
Amperage Readings
V12
69 volts ac (R1 at max.)
a)
Tolerance – ±5% unless specified
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)
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
V14,
V15,
V16
+12 volts dc with Start/Preheat switch S1 in
Preheat position
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,
V24
18 volts ac with Process/Contactor
Control switch S6 in Stick position
TM-4412 Page 42
I1
6.3 amps dc
I2
4.3 – 4.6 amps dc
D502K 5+4
10-4. Waveforms For Section 10-2
1 ms 10 V
1 ms 50 V
gnd
A. DC/CC Open-Circuit Voltage, Voltage/
Amperage Adjust Control R1 At Maximum
gnd
B. DC/CC Output, 28 Volts DC, 200 Amperes,
Amperage Range Switch S3 At 125-400
Position (Resistive Load)
Test Equipment Needed:
D502K 5+4
TM-4412 Page 43
10-5. Filter Board PC6 Testing Information
Y Stop engine.
See Section 10-6 for specific values during testing. Voltage readings tolerance ±10%.
Test Equipment Needed:
803 208 / 192 998
TM-4412 Page 44
D502K 5+4
10-6. Filter Board PC6 Test Point Values
a) Tolerance – ±10% unless specified
b) Reference – to circuit common
(lead 42) unless noted
PC6 Voltage Readings
c) Condition – no load
d) Process/Contactor Control switch
S6 in Weld Terminals Always On –
CC Stick position
Receptacle
Pin
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 between 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
D502K 5+4
Value
TM-4412 Page 45
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
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 Section 10-8)
3
2
Test Equipment Needed:
802 421-C / 192 226-A
TM-4412 Page 46
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.
a) Condition – no load; weld/power
rpm unless noted
b) Voltage/Amperage Adjust Control switch S5 in Panel position
b) Reference – to circuit common
(lead 42) unless noted
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.
OUTPUT
ON/OFF
On
Indicates 24 volts ac input with Process/Contactor Control switch S6 in Weld Terminals Always On position, 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).
COMMAND
On
Indicates 0 to +10 volts dc input from min. to max. of Voltage/Amperage Adjust control R1 with Voltage/
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 is 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.
RPM
LIMIT
On
Indicates engine speed is less than 1704 rpm (approximately).
If LED is on:
. LED
normally
off at weld/
power speed)
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.
AC INPUT
Off
Indicates engine speed is above 1704 rpm (normal operation).
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.
D502K 5+4
TM-4412 Page 47
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:
803 208 / 192 226-A
TM-4412 Page 48
D502K 5+4
10-10. Diagnostic LED’s On LED Board PC9
a) Tolerance – ±10% unless
specified
b) Reference – to circuit common
(lead 42) unless noted
PC9 Voltage Readings
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.
Receptacle
Pin
PLG13
1
Value
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 supply 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 supply 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 supply to PLG13-5. LED lights if okay.
D502K 5+4
TM-4412 Page 49
10-11. Replacing Brushes And Cleaning Slip Rings
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 remove clip and brush from brush
holder assembly. Remove and inspect all three brushes.
Replace brushes if damaged, or if
brush is at or near minimum length.
5
Slip Rings
Visually inspect slip rings. Under
normal use, rings turn dark brown.
1
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
3
4
Minimum Length:
5/8 in (16 mm)
2
New Length: 1-1/4 in (32 mm)
Tools Needed:
Replace
Damaged Brushes
803 209
TM-4412 Page 50
D502K 5+4
10-12. Checking Unit Output After Servicing
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).
1
Y Stop engine before adjusting resistor R3.
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.
2
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-5).
Test Equipment Needed:
Tools Needed:
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
803 210 / 803 201
D502K 5+4
TM-4412 Page 51
SECTION 11 – DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
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. Disconnect 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.
. To aid in reassembly, mark leads
before disconnecting. See lead
list summary in Section 12 for
connection information.
Disconnect:
1
3
2
F
stator weld leads from Amperage Range switch S3
F
stator exciter leads from terminal strip 1T
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
4
Engine
5
Flywheel Housing
6
Front Generator Mounts
Support engine under flywheel housing 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.
5
6
802 431-C
TM-4412 Page 52
D502K 5+4
11-2. Disassembly Of Generator
A
4
E
1
3
2
C
A
B
D
Torques:
D
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)
803 204-A
Y Do not damage stator or rotor windings 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
D502K 5+4
Exciter stator comes off with endbell.
4
Rotor
If engine must also be removed, remove engine 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 53
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
Circuit
Diagram
Serial Or Style Number
D502K 5+4
LC110463 and following
206 628-A
Circuit Board PC4, PC5
(HF Filter)
LC110463 and following
189 746
Circuit Board PC3
(HF Filter)
LC110463 and following
188 607
Circuit Board PC6
(HF Filter )
LC110463 and following
192 997
Circuit Board PC9
(LED)
LC110463 and following
192 227-A
D502K 5+4
Wiring
Diagram
See Table 12-1
TM-4412 Page 55
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
D502K 5+4
TM-4412 Page 57
GND
1
C1
2
C2
3
C3
4
C4
5
C5
COM
189 746
Figure 12-2. Circuit Board PC4, PC5 (HF Filter) Effective With Serial No. LC110463 And Following
19B
19A
19C
C4
C3
C1
27
RV1
R1
37A
37B
17
30C
C2
C5
C6
30B
30A
188 607
Figure 12-3. Circuit Board PC3 (HF Filter) Effective With Serial No. LC110463 And Following
TM-4412 Page 58
D502K 5+4
192 997
Figure 12-4. Circuit Board PC6 (HF Filter) Effective With Serial No. LC110463 And Following
192 227-A
Figure 12-5. Circuit Board PC9 (LED) Effective With Serial No. LC110463 And Following
D502K 5+4
TM-4412 Page 59
Table 12-1. Lead List Summary For D502K 5+4 Eff w/LC110463 And Following
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead
Connections
Lead
Connections
––––B
––––H
0010A
0011A
0012A
0013A
0014A
0015A
0016A
0017A
0017A
0018A
0019A
0019B
0019C
0019D
0019E
0019F
0019J
0021A
0022A
0023A
0024A
0025A
0026A
0027A
0027A
0030A
0030B
0030C
0030D
RC6 (2) – S3 (2)
RC6 (1) – S3 (1)
T1 SEC TO SR4 (AC)
STATOR TO EXIT
#1 COIL TO RANGE SWITCH
#1 COIL TO RANGE SWITCH
#1 COIL TO RANGE SWITCH
#1 COIL TO RANGE SWITCH
#1 COIL TO RANGE SWITCH
#1 COIL TO RECTIFIER
PC3 TO BUS BAR
T1 SEC TO SR4 (AC)
PC3 TO HEAT SINK (+)
PC3 TO LEAD 19 FROM PC1 (E2)
PC3 TO LEAD 19 FROM VOLTMETER (+)
SR3 (+) TO WELD TERMINAL (+)
SR4 (+) TO SR3 (+)
SR5 (+) TO SR3 (+)
PC1 (PLG8–E2) TO LEAD 19 FROM PC3
STATOR TO EXIT
#2 COIL TO RANGE SWITCH
#2 COIL TO RANGE SWITCH
#2 COIL TO RANGE SWITCH
#2 COIL TO RANGE SWITCH
#2 COIL TO RANGE SWITCH
#2 COIL TO RECTIFIER
PC3 TO BUS BAR
PC3 TO HEAT SINK (–)
PC3 TO LEAD 30 FROM PC1 (E1)
PC3 TO LEAD 30 FROM VOLTMETER (–)
SHUNT (OUTSIDE) TO LEAD 30 FROM
AMMETER
SHUNT (INSIDE) TO LEAD 30 FROM AMMETER
SR3 (–) TO WELD TERMINAL (–)
SR4 (–) TO SR3 (–)
SR5 (–) TO SR3 (–)
PC1 (PLG8–E1) TO LEAD 30 FROM PC3
STATOR TO EXIT
#3 COIL TO RANGE SWITCH
#3 COIL TO RANGE SWITCH
#3 COIL TO RANGE SWITCH
#3 COIL TO RANGE SWITCH
#3 COIL TO RANGE SWITCH
PC8 (PLG1–G1) TO PLG6 (3)
RC6 (3) – S3 (3)
#3 COIL TO RECTIFIER
PC1 (PLG8–G2) TO LEAD 37 FROM SR3
PC3 TO BUS BAR
PC3 TO LEAD 37 FROM PLG3 (2)
T1 SEC TO SR5 (AC)
T1 SEC TO SR5 (AC)
STARTER TO AMP METER (POS)
AMP METER (NEG) TO CB10 (COPPER)
0042AB
0042AC
0042AD
0042AE
0042AF
0042BA
0042BB
0042CC
0042DD
0042EE
0042H
0042JJ
0042K
0042KK
0042L
0042L
0042L
0042M
0042N
0042P
0042R
0042S
0042SS
0042T
0042U
0042V
0043A
0043B
0043D
0043E
0044A
0044B
0044C
0044H
0044J
0045A
0046A
0048A
0054A
0055A
0060A
0061A
0061B
0061C
0061CA
0061D
0061E
0061F
0061H
0061J
0061K
BASE GROUND TO D10 (–)
CR5 (85) TO D10 (–)
FUEL SENDER TO BASE GROUND
GROUND CABLE TO OIL PRESSURE SWITCH
FUEL PUMP TO FUEL SENDER
SPLICE A TO SPLICE B
SPLICE TO D10 (NEG)
RC3 (2) TO LEAD 42JJ
SPLICE TO TIMER (NEG)
SPLICE TO HOUR MTER (NEG)
PC1 (PLG8–F3) TO PC8 (PLG13–8)
SPLICE TO LEAD 42 CC
PC1 (PLG8–C1) TO PLG3 (2)
SPLICE TO LEAD 42 SS
END BELL (BOTTOM–LEFT) – PC4 (GND)
END BELL (BOTTOM–RIGHT) – PC5 (GND)
END BELL (TOP–LEFT) – PC6(GND)
ASSY TO TEMP GAUGE (5)
GND STD (BASE) TO GND STUD (AUX PANEL)
1T (C–RIGHT) – GND STUD
GFCI (GND) – GND STUD
RC1 (GND) – GND STUD
SPLICE TO 42KK
076 (K) TO LEAD 42 FROM END BELL
ASSY TO HOUR METER (–)
ASSY TO FUEL GAUGE (5)
START SWITCH (17) TO GLOW PLUGS
START SWITCH JUMPER #17 TO #19
S1 (19) TO D9 (–)
GLOW PLUG TO FS1 (PULL)
CR5 (87A) TO CB10 (SILVER)
CB10 (SILVER) TO START SW (30)
CB10 (SILVER) TO ALT (B)
CR5 (87) TO TIMER (N.O.)
CB10 (SILVER) TO CR1 (30)
CR2 (30) TO FS1
STOP SW (CENTER) TO CR 2 (87A)
LEAD 48B TO S6 (9)
CT2 TO CT1
CT2 TO CT1
D8 (POS) TO ALT (IND)
D10 (+) TO CR1 (86)
D8 (–) TO D9 (+)
SPLICE TO HOUR METER (+)
D9 (+) TO D10 (+)
SPLICE TO FUEL GAUGE (6)
D8 (–) TO CR5 (86)
TIMER (+) TO STOP SW (BOTTOM)
SPLICE TO TEMP GAUGE (6)
SPLICE TO TEMP GAUGE (2)
FUEL PUMP TO CR1 (87A)
0030E
0030F
0030G
0030H
0030J
0031A
0032A
0033A
0034A
0035A
0036A
0036A
0036C
0037A
0037A
0037A
0037B
0038A
0039A
0040A
0041A
TM-4412 Page 60
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
0061N
0061P
0061Q
0061R
0062A
0064A
0066B
0067B
0068B
0069A
0070A
0071A
0081A
0081B
0081D
0081E
0082A
0082B
0083A
0083B
0083D
0084A
0084B
0084D
0084E
0084F
0085A
0085B
0086A
0086D
0087AA
0088A
0088B
0089A
0098A
0099A
0100A
0100B
0101A
0101B
0102C
0102D
0102E
0103A
0103B
0103D
0104A
TIMER (C) TO D8 (NEG)
D8 (–) TO CR2 (86)
TIMER (POS) TO TIMER ”C” (COMMON)
STOP SW BOTTOM TO HOUR METER (POS)
CR1 (87) TO D10 (POS)
TEMP GAUGE (4) TO CR2 (85)
STARTER SOLENOID TO START SW (50)
LEAD FROM CT1 TO PC7 (D)
LEAD FROM CT1 TO PC7 (G)
S6 (10) TO CR6 (30)
CR1 (85) TO OIL SENDER (S12)
COOLENT SENDER TO TEMP GAUGE (3)
FUEL GAUGE (3) TO FUEL SENDER
EXCITER STATOR – 1T (A–LEFT)
CB1 (BOTTOM) – 1T (A–RIGHT)
EXCITER TO T1
T1 PRI TO EXCITER STATOR
EXCITER STATOR – 1T (B–LEFT)
GFCI (N) – 1T (B–RIGHT)
EXCITER STATOR – 1T (C–LEFT)
PC6 (PLG14–10) TO (1T–83C)
PC6 (PLG14–9) TO PC1 (PLG9–F2)
EXCITER STATOR – 1T (D–LEFT)
CB1 (BOTTOM) – 1T (D–RIGHT)
EXCITER TO S6
AUX STATOR TO S6 (11)
1TD TO CB23
CB2 (BOTTOM) – GFCI (HOT)
CB2 (BOTTOM) – PC4 (5)
CB1 (TOP) – RC1 (BOTTOM–RIGHT)
CB1 (TOP) – CB2 (TOP)
CB23 TO PLG14 (2)
CB1 (TOP) – RC1 (BOTTOM–LEFT)
CB1 (TOP) – PC4 (4)
EXCITER TO CB5 (TOP)
S6 (12) TO CB4
T1 PRI TO CB4
EXCITER STATOR – PLG1 (1)
RC1 (1) TO F1
EXCITER STATOR – PLG1 (3)
RC1 (3) TO SR1 (AC)
SR1 (–) TO C9 (–)
RC3 (4) TO C9 (–)
R3 TO PLG3 (4)
EXCITER STATOR – PLG1 (4)
PC1 (PLG8–A1) TO PLG3 (6)
RC3 (6) TO RC1 (4)
EXCITER STATOR – PLG1 (6)
0104B
0105A
0105B
0105D
0105E
0105F
0106A
0106B
0106C
0106D
0106D
0106E
0108A
0108B
0108C
0110A
0110B
0111A
0111B
0113A
0113B
0116A
0117A
0118A
0119A
0120A
0121A
0121B
0122A
0123A
0124A
0125A
0126A
0127A
0128A
0129A
0134A
0135A
0136A
0137A
0138A
0138B
0139A
0140A
0141A
0142A
0143A
0144A
RC1 (6) TO F2
BRUSH (CENTER) – PLG1 (2)
SR1 (+) TO C9
RC3 (8) TO C9 (+)
PC1 (PLG8–D1) TO PLG3 (8)
RC1 (2) TO SR1 (+)
BRUSH (FRONT) – PLG1 (5)
RC1 (5) TO SPLICE
RC3 (7) TO SPLICE
CR4 (6) TO SPLICE
R3 TO PLG3 (7)
SPLICE (A) TO SPLICE (B)
BRUSH (REAR) – PLG1 (8)
RC1 (8) TO RC3 (9)
PC1 (PLG8–A2) TO PLG3 (9)
CB12 TO RC3 (11)
PC1 (PLG8–C2) TO PLG3 (11)
CB12 TO CB11
CB12 TO CR5 (30)
CB11 TO RC3 (12)
PC1 (PLG8–B1) TO PLG3 (12)
PC6 (PLG14–8) TO PC1 (PLG9–B1)
PC6 (PLG14–7) TO PC1 (PLG9–C3)
PC6 (PLG14–6) TO PC1 (PLG9–B2)
S6 (1) TO PC6 (PLG14–5)
S6 (2) TO PC1 (PLG9–F1)
S6 (3) TO PC6 (PLG14–4)
PC6 (PLG14–3) TO CB5
PC1 (PLG9–A1) TO S6 (5)
PC1 (PLG9–A2) TO S6 (6)
S6 (7) TO PC1 (PLG9–D3)
PC1 (PLG8–F1) TO PLG6 (1)
PC1 (PLG8–F2) TO PLG6 (2)
S5 (TOP) TO PC1 (PLG9–B3)
S5 (CENTER) TO PC1 (PLG9–D2)
S5 (BOTTOM) TO PC1 (PLG9–2)
R1 (PLG10–1) TO PC1 (PLG9–D1)
R1 (PLG10–2) TO PC1 (PLG9–C1)
R1 (PLG10–3) TO PC1 (PLG9–A3)
SR1 (AC) TO F1
RC3 (1) TO F2
PC1 (PLG8–A3) TO PLG3 (1)
PC1 (PLG8–C3) TO PC8 (PLG13–1)
PC1 (PLG8–D2) TO PC8 (PLG13–5)
PC1 (PLG8–D3) TO PC8 (PLG13–6)
PC1 (PLG8–K2) TO PC8 (PLG13–7)
PC1 (PLG8–J2) TO PC8 (PLG13–9)
PC1 (PLG8–B3) TO PC8 (PLG13–10)
D502K 5+4
TM-4412 Page 61
SECTION 13 – RUN-IN PROCEDURE
run_in1 8/01
13-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1
2
Welding Generator
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.
.
1
2
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.
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.
TM-4412 Page 62
D502K 5+4
13-2. Run-In Procedure Using Load Bank
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
4
2
1
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
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 maximum 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.
3
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 during 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
D502K 5+4
TM-4412 Page 63
13-3. Run-In Procedure Using Resistance Grid
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
6
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
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.
3
5
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).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
. Check oil level frequently during 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.
S-0684
TM-4412 Page 64
D502K 5+4
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
15
16
17
2
13
85
1
86
82
83
18
87
84
12
88
19
3
4
11
6
9
5
89
10
8
7
90
91
111
92
112
93
110
12
94
95
109 (Fig. 14-5)
103
102
96
104
91
101 (FIG. 14-2)
97
108
98
99
100
106
105
107 (FIG. 14-3)
Figure 14-1. Main Assembly
TM-4412 Page 66
D502K 5+4
Eff w/LC110463 And Following
39
36
37
26
38
27
25
40
33
22
35
24
21
42
23
34
43
30
31
20
30
32
41
44
45
29
28
81
78
77
79
76
80
75
73
74
56
60
59
6261
58
57
31
63
64
70
71
72 (Fig 14-4)
49
48
46
47
65
66
67
68
50
57
51
69
53
52
55
54
803 201
D502K 5+4
TM-4412 Page 67
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly
. . . 1 . . . . . . . . . . . . . +199294
. . . 2 . . . . . . . . . . . . . +199301
. . . 3 . . . . . Z1 . . . . . 202647
. . . 4 . . . . . 1T . . . . . 038621
. . . 5 . . . . . . . . . . . . . . 038620
. . . 6 . . . . . . . . . . . . . . 081499
. . . 7 . . . . . . . . . . . . . . 206352
. . . 8 . . SR4, SR5 . . 035704
. . . 9 . . . . CB4 . . . . 045061
. . . 10 . . . . . . . . . . . . . . 201697
. . . 11 . . . . . T1 . . . . . 205636
. . . 12 . . . . . . . . . . . . . . 173352
. . . 13 . . . . . . . . . . . . . . 189708
. . . 14 . . . . . . . . . . . . . . 200968
. . . 15 . . . . . . . . . . . . . . 206393
. . . 16 . . . . . . . . . . . . . . 189763
. . . 17 . . . . . . . . . . . . . . 189764
. . . . . . . . . . . . . . . . . . . . 192938
. . . . . . . . . . . . . . . . . . ♦192939
. . . 18 . . . . . . . . . . . . . . 189464
. . . 19 . . . . . . . . . . . . . . 206351
. . . 20 . . . . . . . . . . . . . +206541
. . . 21 . . . . . . . . . . . . . . 189052
. . . 22 . . . . . . . . . . . . . . 190198
. . . 23 . . . . . . . . . . . . . . 176103
. . . 24 . . . . . . . . . . . . . . 176104
. . . 25 . . . . . . . . . . . . . . 176230
. . . 26 . . . . . . . . . . . . . . 105734
. . . 27 . . . . . . . . . . . . . . 202629
. . . 28 . . . . . . . . . . . . . . 202633
. . . 29 . . . . . . . . . . . . . . 010875
. . . 30 . . . . . . . . . . . . . . 176106
. . . 31 . . . . . . . . . . . . . . 206388
. . . 32 . . . . . . . . . . . . . . 206517
. . . . . . . . . . . . . . . . . . . . 206518
. . . . . . . . . . . . . . . . . . . . 605982
. . . . . . . . . . . . . . . . . . . . 206384
. . . 33 . . . . . . . . . . . . . . 207192
. . . 34 . . . . . . . . . . . . . . 207005
. . . 35 . . . . . . . . . . . . . . 207188
. . . 36 . . . . . . . . . . . . . . 190206
. . . 37 . . . . . . . . . . . . . . 190207
. . . 38 . . . . . . . . . . . . . . 108081
. . . 39 . . . . . . . . . . . . . . 203430
. . . 40 . . . . BATT . . . . 190896
. . . 41 . . . . . . . . . . . . . . 201006
. . . 42 . . . . . . . . . . . . . +202639
. . . 43 . . . . . . . . . . . . . . 176108
. . . 44 . . . . . . . . . . . . . . 207193
. . . 45 . . . . . . . . . . . . . . 206387
. . . 46 . . . . . . . . . . . . . . 190992
. . . 47 . . . . . . . . . . . . . . 206604
. . . 48 . . . . . . . . . . . . . . 190126
. . . 49 . . . . . . . . . . . . . . 206999
. . . 50 . . . . . . . . . . . . . . 199338
TM-4412 Page 68
. . Panel, Gen Lh Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Engine Side Stainless Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Reactor, AC Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . . 1
. . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Rectifier, Integ Bridge 40 Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pan, Reactor & rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Extrusion, Rubber Clamp/Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 ft
. . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Elbow Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Air Cleaner Intake Kubota V3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Cleaner, Intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Tank Screw–on 3.500 In W/Vent W/Lanyard (included w/tank) . . . . 1
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Radiator Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Cover E–coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 6
. . Guard, Fan (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Radiator, W/Shroud & 7# Cap 4row Core Assy Rda (consisting of) . . . . . 1
. . . . Radiator, Big Blue Air Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Cap, Radiator Pressure 7 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Shroud, Radiator Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Engine Extension L.h. Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Grill, Rear Panel Stainless Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Rear Radiator Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Low Mainte (Dry) . . . . . . . . . . . 1
. . Bolt, J Stl .312–18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cover, Battery Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Engine Extension R.h. Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Paddle Series 20 (Ss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Maintenance D502k 5+4 Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Door, Engine Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D502K 5+4
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . . 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
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 199300 . . Panel, Gen Rh Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 206391 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199507 . . Hose Assy, Oil Drain 20”lg (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . . . . . . . . . . . . . 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
. . . 74 . . . . . . . . . . . . . . 198990 . . Adapter, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . S12 . . . . 187542 . . Switch, Pressure Oil 11psi No Cont Frict Term . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . TEMP SNDR . . 193231 . . Sender, Coolant Temp 300 Deg F 1/2–14 Npt . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 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
. . . . . . . . . . . . . . . . . . . . 207722 . . Gasket, Exhaust Manifold Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . . . . . . . . . . . . . 107816 . . . . Hose, Sae .250 Id X .500 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 ft
. . . 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
D502K 5+4
TM-4412 Page 69
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . 100 . . . . R3 . . . . . 189699
. . 101 . . . . . . . . . Figure 14-2
. . 102 . . . . . . . . . . . . . 191512
. . 103 . . . . . . . . . . . . . 189731
. . 104 . . . . . . . . . . . . . 199305
. . 105 . . . . . . . . . . . . . 202637
. . 106 . . . . . . . . . . . . . 200910
. . 107 . . . . . . . . . Figure 14-3
. . 108 . . . . . . . . . . . . . . . . . . ♦
. . 109 . . . SR3 Figure 14-5
. . 110 . . . . . . . . . . . . . 193453
. . 111 . . . PC1 . . . . 207397
. . 112 . . . . . . . . . . . . . 203260
. . . . . . . . . . . . . . . . . . . . 191819
. . . . . . . . . . . . . . . . . . . . 095636
. . . . . . . . . . . . . . . . . . . . 198584
. . . . . . . . . . . . . . . . . . . . 049525
. . . . . . . . . . . . . . . . . . . . 190058
. . . . . . . . . . . . . . . . . . . . 206993
+
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . .
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Top Front Upright Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upright, Front Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock And Moving Parts CE . . . . . . . . . . . . . . . .
Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Sae .312 Id X .560 Od X 14.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Sae .187 Id X .410 Od X 30.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Sae .312 Id X .560 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 312–18 U–nut Multi–thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 250–20 U–nut Multi–thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Label (Includes safety and informational labels) . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
2
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
12
3
16
5
15
2
11
1
8
9
10
6
7
14
803 203
Figure 14-2. Control Box Assembly
TM-4412 Page 70
D502K 5+4
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-2. Control Box Assembly (Figure 14-1 Item 101)
. . . 1 . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo–blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 201077 . . . Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
. . . 7 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box,Weld Control L.h. (consisting of) . . . . . . . . . . . . . . .
. . . 10 . . CB11, CB12 . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . SR1 . . . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . .
. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . .
. . . 12 . . CR1, CR5 . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . .
. . . 13 . . . . CR2 . . . . 173069 . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . T . . . . . . 207139 . . Timer, Delay On Make/Break Open 3–60 Sec 12vdc . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206398 . . Harness, Engine Kubota V3300 (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S7 . . . . . 199691 . . . . Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (located on
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . front panel, see Figure 14-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . 16 . . . D8/C8 . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D9/C9
D10/C10
2
2
1
1
1
3
1
1
1
1
2
1
1
1
2
1
1
1
1
1
3
2
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.
D502K 5+4
TM-4412 Page 71
Eff w/LC110463 And Following
. Hardware is common and
not available unless listed.
3
2
4
1
5
6
8
9
7
45
10
44
11
12
43
13
14
15
42
41
40
33
39
16
36 35
33
37
38
19
32
34
31
30
17
18
20
21
22
29
23
28
27
26
25
24
803 202
Figure 14-3. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 107)
... 1 ..............
... 2 ..............
. . . 3 . . . . . S3 . . . . .
....................
. . . . . . . . . . RC6 . . . .
. . . 4 . . . . . R1 . . . . .
TM-4412 Page 72
206212
206382
208278
192558
148389
193118
. . Plate, Screened Ident Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Engine/Weld Control Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Harness, Range Switch (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn,Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
. . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
D502K 5+4
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Continued)
. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . .
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC10 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . CB13 . . . . 139266 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S1 . . . . . 207720 . . Switch, Ignition 3 Position (Mom–off–mom) W/Handle . . . . . . . . . . . . . . .
. . . 11 . . . . . S7 . . . . . 199691 . . Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine harness, see Figure 14-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (consisting of) . . . . . . . . . . . . . . . . .
. . . 13 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . . 14 . . . GFCI-1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5–20r Gfi . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . RC1 . . . . 147632 . . . . Rcpt, Tw Lk Grd 2p3w 30a 250v *L6–30r . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts CE . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . +202641 . . Panel, Auxiliary Power Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 601836 . . Nut, 250–20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250–20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . ♦196073 . . Label, Do Not Switch While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . . . . . ♦ . . Switch, Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 199303 . . Panel, Mtg Terminal Power Output Stainless . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . PC4, PC5 . . 189744 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . NEGATIVE . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . . . . . . ♦ . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . . . . . . ♦ . . Pin, Spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . POSITIVE . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 193260 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 193258 . . Cover, Receptacle Gfci Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . HM . . . . . 118058 . . Meter, Hour 12–24vdc 2.25 Dia High Profile Stainles . . . . . . . . . . . . . . . .
. . . 38 . . . . . AM . . . . . 118060 . . Meter, Amp Dc 60–0–60 2.250 Dia High Profile Stainl . . . . . . . . . . . . . . . .
. . . 39 . . . . TEMP . . . 193229 . . Gauge, Coolant Temp 0– 300 Deg F Electric Switch . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . . . . . . ♦ . . Meter, Weld Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . . . . . . ♦ . . Meter, Weld Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
D502K 5+4
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
3
1
1
1
1
2
1
8
2
2
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
TM-4412 Page 73
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Continued)
....................
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . PLG13 . . .
. . . . . . . . . . PLG3 . . . .
....................
....................
....................
....................
....................
....................
♦Optional
+
193158
114063
193184
147992
158465
088731
135873
187654
196602
024103
120304
. . Harness, Unit Weld Control – CV (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap–in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . .
. . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plug, Cavity 18, 30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . .
. . Blank, Snap–in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Blank, Snap–in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
10
1
2
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.
20
. Hardware is common and
not available unless listed.
17
13
18 19
16
21
15
12
9
10
14
22
11
23
8
24
7
6
5
25
3
18
4
2
30
28
29
26
27
31
33
1
29
32
34
35
803 204-A
Figure 14-4. Generator
TM-4412 Page 74
D502K 5+4
Eff w/LC110463 And Following
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-4. Generator (Figure 14-1 Item 72)
. . . 1 . . . . . . . . . . . . . . 132053
. . . 2 . . . . . . . . . . . . . . 183387
. . . 3 . . . . . . . . . . . . . . 195911
. . . 4 . . . . . . . . . . . . . . 143220
. . . 5 . AUX STATOR . 201099
. . . 6 . WELD STATOR +208287
. . . 7 . . . . . . . . . . . . . . 013367
. . . 8 . . . . . . . . . . . . . . 190197
. . . 9 . . . . . . . . . . . . . . 172674
. . . 10 . . . . . . . . . . . . . . 191580
. . . 11 . . . . . . . . . . . . . . 208216
. . . 12 . . . . . . . . . . . . . . 039207
. . . 13 . . . REV FLD . . . 202452
. . . 14 . . . . . . . . . . . . . . 024617
. . . 15 . . . . . . . . . . . . . . 053390
. . . 16 . . . . . . . . . . . . . . 195547
. . . 17 . . . . . . . . . . . . . . 049026
. . . 18 . . . . . . . . . . . . . . 083883
. . . 19 . . . . . . . . . . . . . . 202302
. . . 20 . . . . . . . . . . . . . . 206380
. . . 21 . . . . . . . . . . . . . . 605231
. . . 22 . . . . . . . . . . . . . . 194512
. . . 23 . . . . . . . . . . . . . . 183387
. . . 24 . . . . . . . . . . . . . . 198631
. . . 25 . . . . . . . . . . . . . . 191579
. . . 26 . . . . . . . . . . . . . . 172555
. . . 27 . . . . . . . . . . . . . . 602159
. . . 28 . . . . . . . . . . . . . . 604950
. . . 29 . . . . . . . . . . . . . . 602211
. . . 30 . . . . . . . . . . . . . . 139341
. . . 31 . . . . . . . . . . . . . *190823
. . . 32 . . . . . . . . . . . . . . 188560
. . . 33 . . . . . . . . . . . . . . 189142
. . . 34 . . . . . . . . . . . . . . 602242
. . . 35 . . . . . . . . . . . . . . 604534
. . . . . . . . . . . . . . . . . . . . 190259
. . . . . . . . . . PLG1 . . . . 168071
. . . . . . . . . . . . . . . . . . . . 187651
. . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Conical Spring .406 Id X .875 Od Pltd . . . . . . . . . . . . . . . . . . . . . .
. . Endbell, Gen (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-ring, 2.859 Id X .139cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Exciter/Aux Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Weld Assembly Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spring, Ext .240 Od X .041 Wire X 3.500pld . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Stl Kubota V3300 18ga Generator . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rotor, Gen (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Rtng Ext 1.375 Shaft X .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M10-1.5 X 25hexhd Pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .042 Id X 0.709 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plate, Flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M10-1.5 X 35hexhd Pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Flat 1.250 Od X .406 Id X 7 Ga Thk Stal Pld . . . . . . . . . . . . . . .
. . Washer, Cone .380 Id X .860od X .109t Stl Pld 4000lbs . . . . . . . . . . . . . .
. . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M10-1.5 X 50hexhd Pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, .312-18 X .75hexwhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, .312-18 X 2.25hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318 Id X 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brush, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brushholder Assembly, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 312–18x1.25 Hex Hd–pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Harness, Brush (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg . . . . . . . . .
. . . . Seal, Wire Univ 9p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
14
1
1
1
2
1
2
1
1
1
1
1
1
1
8
8
1
1
4
4
4
4
2
6
2
4
4
4
3
3
1
2
2
1
1
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.
D502K 5+4
TM-4412 Page 75
Eff w/LC110463 And Following
. Hardware is common and
not available unless listed.
4
3
2
1
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 . . . .
... 1 ..............
... 2 ..............
... 3 ..............
... 4 ..............
. . . 5 . . . . PC3 . . . .
... 6 ..............
... 7 ..............
. . . 8 . D3, D5, D7 .
. . . 9 . D2, D4, D6 .
208279
188137
188517
188135
134201
201449
188136
188493
208334
208335
. . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
2
3
1
8
2
3
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
Purchase Date
Serial/Style Number
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Contact the Delivering Carrier for:
Zip
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
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