D502K5+4 Technical Manual

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
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WARNING
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
This product, when used
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 for welding or cutting,
produces fumes or
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
gases which contain
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 chemicals known to the
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 State of California to
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 cause birth defects and,
in some cases, cancer.
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(California Health &
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Code Section
3-6. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 25249.5 et seq.)
3-7. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-1. Installing Welding Generator (See Section 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WARNING
4-2. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Battery posts, terminals
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 and related accessories
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 contain lead and lead
compounds, chemicals
4-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 known to the Sate of
4-6. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 California to cause
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 cancer and birth defects
or other reproductive
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
harm. Wash hands after
4-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 handling.
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CALIFORNIA
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-3. Process/Contactor Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Proposition 65
5-4. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Warning
Diesel engine exhaust and
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
some of its constituents
6-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 are known to the State of
California to cause cancer,
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
birth defects, and other
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 reproductive harm.
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-4. Inspecting/Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 – EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 10 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . . 40
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . . 42
10-4. Waveforms For Section 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9 . . . . . . . . . . . . . . . . . . . . 46
10-8. Using Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10-9. LED Board PC9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-10.Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-11. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10-12.Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
(Continued)
TABLE OF CONTENTS
SECTION 11 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 12 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION 13 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SECTION 14 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_rtm 7/99 / OM-4412
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. 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 STATIC (ESD) can damage PC boards.
the symbol, watch out, and follow the related instructions to
D Put on grounded wrist strap BEFORE handling
avoid the hazard.
boards or parts.
Y Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
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 un- D Do not breathe exhaust fumes.
less the procedure specifically requires an en- D Use in open, well-ventilated areas, or vent ex-
ergized unit. haust outside and away from any building air in-
D Insulate yourself from ground by standing or working on dry insu- takes.
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping D Stop engine and let it cool off before checking or
engine on inverters. adding fuel.
D Stop engine on inverter and discharge input capacitors according D Do not add fuel while smoking or if unit is near
to instructions in Maintenance Section before touching any parts. any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.

D Keep away from moving parts such as
fans, belts, and rotors.
BATTERY EXPLOSION can BLIND.
D Have only qualified people remove
guards or covers for maintenance and D Always wear a face shield, rubber gloves, and
troubleshooting as necessary. protective clothing when working on a battery.
D Keep hands, hair, loose clothing, and tools away from mov- D Stop engine before disconnecting or connect-
ing parts. ing battery cables.
D Before working on generator, remove spark plugs or injec- D Do not allow tools to cause sparks when working on a battery.
tors to keep engine from kicking back or starting. D Do not use welder to charge batteries or jump start vehicles.
D Block flywheel so that it will not turn while working on gener- D Observe correct polarity (+ and –) on batteries.
ator components.
D Disconnect negative (–) cable first and connect it last.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face
D Do not tip battery.
shield during servicing.
D Replace damaged battery.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing. D Flush eyes and skin immediately with water.
D502K 5+4 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 D Do not put any body part under unit while lifting.
cold to avoid scalding. D Always use proper equipment (hoists, slings,
D Always check coolant level at overflow tank, if chains, blocks, etc.) of adequate capacity to lift
present on unit, instead of radiator. and support components (stator, rotor, engine,
etc.) as needed during job.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two PINCH POINTS can injure.
statements. 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 High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Pacemaker wearers keep away from servicing communications equipment.
areas until consulting your doctor. D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
FALLING UNIT can cause injury. D If notified by the FCC about interference, stop using the equip-
ment at once.
D Use equipment of adequate capacity to lift and
support unit and components. D Have the installation regularly checked and maintained.
D Use lifting eye to lift unit only, NOT running D Keep high-frequency source doors and panels tightly shut, keep
gear, gas cylinders, or any other accessories. spark gaps at correct setting, and use grounding and shielding to
D Securely attach components to lifting equip- minimize the possibility of interference.
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
HOT PARTS can cause severe burns.
D Reduce current or reduce duty cycle before
D Allow cooling period before servicing. starting to weld again.
D Wear protective gloves and clothing when D Do not block or filter airflow to unit.
working on a hot engine.
D Do not touch hot engine parts bare-handed.
READ INSTRUCTIONS.
SHOCK HAZARD from testing. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Stop engine before making or changing meter
lead connections. D Consult the Owner’s Manual for welding safety
precautions.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip. D Use only genuine replacement parts.
D Read instructions for test equipment. 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 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from
committee’s judgment, has not demonstrated that exposure to power- operator as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-4412 Page 2 D502K 5+4

SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)
Engine Oil
Starting Aid Battery (Engine) Engine Oil
Pressure
Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)
Certified/Trained
Positive Negative Welding Arc
Mechanic
A Amperes
V Volts Panel/Local Remote
Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature
Stick (SMAW) Constant Current MIG (GMAW)

TIG (GTAW)
Welding (CC) Welding
Time
h
Hours
s
Seconds
1 Single Phase
Read Operator’s Do Not Switch

3 Three Phase
Manual
Circuit Breaker
While Welding
Engine-Driven,
Electrode
Connection
Work Connection G
Three-Phase
Alternator With
Rectifier
Hz Hertz
Contactor On
D502K 5+4 TM-4412 Page 3

SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Weld Maximum
Welding Rated Welding Fuel
Output Open-Circuit Auxiliary Power Rating Engine
Mode Output Capacity
Range Voltage
CC/DC 20 – 600 A 500 A, 40 Volts DC, 95 Standard: Kubota V3300-B

100% Duty Cycle Single-Phase, Water-Cooled, Four 25 gal
CV/DC 600 A, 44 Volts DC, 4 kVA/kW, 20/17 A, Cylinder, 49 HP Diesel (95 L)
14 – 40 V 40% Duty Cycle 56 120/240 V AC, 50/60 Hz Engine
3-2. Dimensions, Weights, And Operating Angles
Dimensions
50 in (1270 mm) G
Height
(to top of muffler)
28-1/2 in (724 mm)

(mtg. brackets turned in) Y Do not exceed tilt angles or engine could
Width be damaged or unit could tip.
30-3/4 in (781 mm) Y Do not move or operate unit where it could
(mtg. brackets turned out) tip.
Depth 69-1/2 in (1765 mm)
A 69-1/2 in (1765 mm)
B* 55-7/8 in (1419 mm) A
B C
C* 46-3/8 in (1178)
D* 9-1/2 in (241 mm)
E 27-1/2 in (699 mm)
30°
F 1 in (25 mm) H
30°
20°
G 29-1/2 in (749 mm)
D
H
9/16 in (14 mm) Dia. Front Panel End 20°
4 Holes
* With mounting brackets in center F

position. Dimensions vary with loca- E
tion of mounting brackets.
Weight
802 161-A
No fuel: 1808 lb (820 kg) 803 122
TM-4412 Page 4 D502K 5+4

3-3. Volt-Ampere Curves
The volt-ampere curves show the
A. Stick Mode minimum and maximum voltage
and amperage output capabilities of
100 the welding generator. Curves of all
other settings fall between the
Ranges curves shown.
300 – Max
80 185 – 525
125 – 400
85 – 250
DC VOLTS
55 – 125
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. MIG Mode
100
80
DC VOLTS
60 MAX
40
20 MIN
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode
100
Ranges
60–450
80 40–330
30–220
20–110
DC VOLTS
60
40
20
0
0 100 200 300 400 500 600 700
DC AMPERES
208 135 / 203 415 / 208 136
D502K 5+4 TM-4412 Page 5

3-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
US GAL./HR.
LITERS/HR.
11.35 3.00
10.40 2.75
9.46 2.50
8.51 2.25
7.57 2.00
6.62 1.75
5.67 1.50
4.73 1.25
3.78 1.00
2.84 0.75
1.98 0.50
0.95 0.25
0.00 0.00
0 100 200 300 400 500 600 700
DC WELD AMPERES AT 100% DUTY CYCLE
208 137
3-5. Duty Cycle And Overheating

100% Duty Cycle At 500 Amperes Duty Cycle is percentage of 10 min-
utes 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 aux-
iliary power in amperes available at
the 120 and 240 volt receptacles.
150 300
125 250
AC VOLTS
100 200
75 150
50 100
25 50
0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE
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
18 in (460 mm)
(460 mm)
OR
OR
18 in 18 in
(460 mm) (460 mm)
Grounding Y Always securely fasten weld-

ing generator onto transport
vehicle or trailer and comply
3 with all DOT and other appli-
1 4 cable codes.
GND/PE
Y Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
OR electricity hazards.
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding Terminal
Electrically bond generator frame to 4 Grounding Cable
vehicle frame by metal-to-metal
2 contact. 2 Use #10 AWG or larger insulated
copper wire.
Y If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected 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 di-

rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in 803 122 / Ref. 802 169 / Ref. 202 705
TM-4412 Page 8 D502K 5+4

4-3. Mounting Welding Generator
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
1 brackets or bolt unit down.
1 Mounting Bracket
2 1/2 in Bolt And Washer
(Minimum – Not Supplied)
3 3/8-16 x 1 in Screws
(Supplied)
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
Welding Unit In Place
To Bolt Unit In Place:
Bolting Unit In Place
2 Remove hardware securing the
1 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).
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 802 168-E / Ref. 202 705 / 802 313 / S-0756-C
D502K 5+4 TM-4412 Page 9

4-5. Engine Prestart Checks
Remove air bleed screw Check radiator coolant

when filling radiator. level when fluid is low in
See Section 4-6. recovery tank.
Full
Full
Capacity: w/Overflow
Diesel Tank 10 qt (9.5 L)
Full
Coolant Recovery
Tank
Full
803 123-A
. Check all engine fluids daily. tions). Leave filler neck empty to allow room
for expansion.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
Engine must be cold and on a level surface. of 50% antifreeze and 50% water must be
Unit is shipped with 20W break-in oil. The Do not run out of fuel or air may enter fuel
used in this engine. Do not use 100% anti-
Automatic shutdown system stops engine if system and cause starting problems. See
freeze or severe damage will occur.
engine manual to bleed air from fuel system.
oil pressure is too low or coolant tempera- Keep radiator and air intake clean.
ture is too high. Oil
Y Incorrect engine temperature can
. This unit has a low oil pressure shut- After fueling, check oil with unit on level sur- damage engine. Do not run engine
down switch. However, some condi- face. If oil is not up to full mark on dipstick, without a properly working thermo-
tions may cause engine damage before add oil (see maintenance label). stat and radiator cap.
the engine shuts down. Check oil level Y Engine may use oil and wetstacking . To improve cold weather starting:
often and do not use the oil pressure may occur during run-in. Check oil Use Engine Start/Preheat switch to op-
shutdown system to monitor oil level. several times daily during run-in. erate glow plug (see Section 5-1).
Follow run-in procedure in engine manual. Coolant
If unburned fuel and oil collect in exhaust Keep battery in good condition. Store
Check coolant level in radiator before start-
pipe during run-in, see Section 13. battery in warm area off concrete sur-
ing unit the first time. Add coolant if below
face.
Fuel bottom of filler neck (see Section 4-6 for ra-
diator filling instructions).
Y Do not use gasoline. Gasoline will Use fuel formulated for cold weather
damage engine. Check coolant level in recovery tank daily. (diesel fuel can gel in cold weather).
If coolant is below Cold Full level, add cool- Contact local fuel supplier for fuel in-
Y Do not use ether to start engine.
ant until level in tank is between Cold Full formation.
Add fresh diesel fuel before starting to pre- and Hot Full levels. If recovery tank coolant
vent air from entering the fuel system (see level was low, check coolant level in radiator Use correct grade oil for cold weather
engine maintenance label for fuel specifica- (see Section 4-6). (see Section 7-1).
TM-4412 Page 10 D502K 5+4

4-6. Adding Coolant To Radiator
. Check coolant level according

to Section 4-5 before starting
this procedure.
Engine coolant is a mixture of water
and ethylene glycol base anti-
freeze. 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 cool-
ant to radiator until coolant is at bot-
tom of filler neck. This ensures all
air is purged from the system.
Reinstall air bleed screw and radia-
tor cap. Check coolant level in re-
covery 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
803 122
Y Stop engine. (DCEN), reverse cable connections. tive (–) terminal on right. Use Process/Con-
tactor Control switch to select type of weld
1 Positive (+) Weld Output Terminal
If equipped with optional polarity switch, output (see Section 5-3).
2 Negative (–) Weld Output Terminal connect electrode holder cable to Electrode
terminal on left and work cable to Work ter- For Direct Current Electrode Negative
For Stick and TIG welding Direct Current
minal on right. (DCEN), reverse cable connections.
Electrode Positive (DCEP), connect elec-
trode holder cable to Positive (+) terminal on
For MIG and FCAW welding Direct Current If equipped with optional polarity switch,
left and work cable to Negative (–) terminal
Electrode Positive (DCEP) on CC/CV mod- connect wire feeder cable to Electrode ter-
on right.
els, connect wire feeder cable to Positive minal on left and work cable to Work termi-
For Direct Current Electrode Negative (+) terminal on left and work cable to Nega- nal on right.
TM-4412 Page 12 D502K 5+4

4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Stop engine before 10 – 60% 60 – 100%
connecting to weld out- Welding
Duty Duty 10 – 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
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)
2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)
* Thischart 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.
24 VOLTS AC
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.

REMOTE
OUTPUT
CONTROL E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz

I ac. Protected by circuit breaker
OR CB13.
115 VOLTS AC
Contact closure to I completes

J 115 volt ac contactor control
circuit.
K Chassis common.
803 122
GND
NEUTRAL G Circuit common for 24 and 115

volt ac circuit.
*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
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 Fuel Gauge perage within range selected by Amperage
Range switch. With Process/Contactor Con-
1 Start/Preheat Switch Use gauge to check fuel level when engine is
trol switch in any MIG position, use control to
running.
Use switch to start engine and operate glow adjust voltage. With Voltage/Amperage Adjust
plug for cold weather starting. 5 Battery Ammeter Control switch (item 10) in Remote position,
control limits the remote amperage in TIG
Engine runs at weld/power speed Use gauge to check amperage output to the
mode, but has no effect in Stick and MIG
continuously. battery. The gauge reads near 0 (zero) when
modes.
Turn switch to Preheat position to operate the the engine is running. If gauge is at a negative
glow plug and heat the combustion chambers number, the battery is discharging. Weld output would be about 263 A DC with
before cranking engine (see starting instruc- Y Stop engine, and do not run engine un- controls set as shown (50% of 125 to 400 A).
tions following). til problem is fixed.
2 Engine Shutdown Switch
. The numbers around the control are for
6 Engine Temperature Gauge reference only and do not represent an ac-
Push switch down to stop engine. Normal temperature is 170 - 205° F (77 - 96° tual percentage value.
To Start: C). Engine stops if temperature exceeds 221°
F (105° C). 10 Voltage/Amperage Adjust Control Switch
. If engine does not start, let engine come to Weld Controls
And Remote 14 Receptacle
a complete stop before attempting restart. Use switch to select front panel or remote volt-
7 Process/Contactor Control Switch
Above 41 F (5 C): turn Start/Preheat switch age/amperage control. For remote control,
to Preheat position for 5 seconds and then turn See Section 5-3 for Process/Contactor Con- place switch in Remote position and connect
switch to Start position. Release Start/Preheat trol switch information. remote control to Remote 14 receptacle RC14
switch when engine starts. (see Sections 4-9 and 5-4).
8 Amperage Range Switch
Below 41 F (5 C): Y Do not switch under load. 11 Polarity/AC Selector Switch (Optional)
Turn Start/Preheat switch to Preheat position
for 15 seconds and then turn switch to Start. Use switch to select weld amperage range. Y Do not switch under load.
Release Start/Preheat switch when engine Use the lowest four ranges for Stick and TIG
starts. Use switch to change weld output. Select ei-
welding. Read the upper set of numbers at ther DC Electrode Positive (DCEP) or DC
To Stop: each range for Stick welding and the lower set Electrode Negative (DCEN).
at each range for TIG welding.
Push Engine Shutdown switch down to stop Weld Meters
engine. Use the highest range for MIG welding and for
cutting and gouging (CAC-A). 12 DC Voltmeter (Optional)
3 Engine Hour Meter
For most welding applications, use lowest am-
Use meter to monitor engine running time for Voltmeter displays voltage at the weld output
perage range possible to help prevent arc out-
scheduling maintenance. terminals, but not necessarily the welding arc
ages.
due to resistance of cable and connections.
Engine Gauges 9 Voltage/Amperage Adjust Control
13 DC Ammeter (Optional)
. To read gauges with engine off, turn Start/ With Process/Contactor Control switch in any
Preheat switch to Preheat position. Stick or TIG setting, use control to adjust am- Ammeter displays amperage output of the unit.
D502K 5+4 TM-4412 Page 17

5-3. Process/Contactor Control Switch
206 212-A
1 Process/Contactor Control Switch Section 5-4). Use Weld Terminals Always On – CC Stick
(See Section 5-1 For Location) position for air carbon arc (CAC-A) cutting
and gouging.
Place switch in Weld Terminals Remotely
Y Weld output terminals are energized When switch is in a Weld Terminals Always
Controlled positions to turn weld output on
when Process/Contactor Control On – CC Stick position, the arc drive (dig)
switch is in a Weld Terminals Always and off with a device connected to the re-
circuit provides additional amperage during
On position and the engine is mote 14 receptacle.
low voltage (short arc length conditions) to
running. prevent “sticking” electrodes.
Place switch in Weld Terminals Always On The arc drive (dig) circuit is disabled when
Use switch to select weld process and weld positions for weld output to be on whenever switch is in MIG, TIG, and CC stick (With
output on/off control (see table below and the engine is running. Remote On/Off Control) positions.
Process/Contactor Control Switch Settings
Switch Setting Process Output On/Off Control
GTAW With HF Unit, Pulsing Device,

Weld Terminals Remotely Controlled – CC TIG At Remote 14 Receptacle
Or Remote Control
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
Stick (SMAW),
Weld Terminals Always On – CC Stick Electrode Hot
Air Carbon Arc (CAC-A) Cutting And Gouging
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).
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 Set Remote
Set Range Control Not Adjust Optional Remote Control
Adjust Switch Process
Used In Remote
Stick Mode
Example: Combination Remote Amperage Control (TIG) With Remote On/Off 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 Set Remote
Set Range Set Control Adjust Optional Remote Control
Adjust Switch Process
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.
1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 30 A AC Twistlock
Receptacle RC1
1 2 Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
3
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-

4 gine at weld/power speed and
press test button to verify GFCI
is working properly.
3 Circuit Breaker CB1
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles 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 . See also Engine Manual and Maintenance Label.

engine Service engine more often if used in severe condi-
fluids. tions.
* To be done by Factory Authorized Service Agent.
8h
Coolant
Full Check Fluid
Wipe Up
Levels. See
Spills.
Section 4-5.
OIL
Full
50 h
Clean And
Check Fuel Lines Tighten Weld
And Connections. Terminals.
100 h
Check Air Cleaner Check

Clean Air Filter. 1/2 in.
Hoses For Cracks (13 mm) Belt
See Section 7-3.
And Loose Clamps. Tension.
Clean And
Tighten
Battery
Connections.
200 h
Change Oil Filter.

Change Oil. See See Section 7-6.
Section 7-6. Service More Often
In Dirty Conditions.
Check
Radiator
Hoses And
Clamps.
250 h
Replace
Unreadable
Labels.
TM-4412 Page 22 D502K 5+4

500 h
Replace Fan Belt. Air Hose Clean Radiator

Exterior.
Check And
Repair Or
Clean Spark
Replace
Arrestor. See
Cracked
Section 7-4.
Cables.
800 h
Replace Secondary Fuel Replace Primary

Filter. See Section 7-6. Fuel Filter. See
Section 7-6.
Check Valve
Clearance.*
1000 h
Service Welding
Drain Sludge Generator Brushes
FUEL From Fuel And Slip Rings.
SLUDGE Tank. See Service More Often
Section 7-6. In Dirty Conditions.*
Blow Out Or
Vacuum Inside.
OR During Heavy
Service,
Clean Monthly.
1500 h
Clean/Set
Injectors.*
1 Year
Replace Air
Filter Element(s).
See Section 7-3.
2 Years
Replace Radiator
Coolant And Hoses.
See Section 7-7.
D502K 5+4 TM-4412 Page 23

7-3. Servicing Air Cleaner
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element. En-
1 2 3 4 gine damage caused by using a
damaged element is not covered
by the warranty.
. The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
Optional makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Keep nozzle 1 Housing
2 in (51 mm)
from element. 2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
Blow Inspect
(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 ele-
ment 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

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe With Raincap
3 1
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.
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
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency 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
Tools Needed:
803 123-A
TM-4412 Page 26 D502K 5+4

7-6. Servicing Fuel And Lubrication Systems
Tools Needed:
4
5
Right Side
6 2
1
Ref. 800 159-E / Ref. 802 170 / 803 123-A
Y Stop engine and let cool. To drain water from fuel system: To drain sludge from fuel tank:
Y After servicing, start engine and Open primary fuel filter petcock and drain
check for fuel leaks. Stop engine, water into metal container. Close petcock Y Beware of fire. Do not smoke and
tighten connections as necessary, when water-free fuel flows. keep sparks and flames away from
and wipe up spilled fuel. drained fuel. Dispose of drained fuel
To replace primary fuel filter: in an environmentally-safe manner.
1 Oil Filter
Turn filter counterclockwise. Remove filter. Do not leave unit unattended while
2 Oil Drain Valve And Hose draining fuel tank.
3 Oil Fill Cap Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clock-
4 Primary Fuel Filter (In-Line)
wise. Bleed air from fuel system according Y Properly lift unit and secure in a level
5 Secondary Fuel Filter to engine manual. position. Use adequate blocks or
stands to support unit while drain-
6 Fuel Tank Sludge Drain Valve Inspect fuel line, and replace if cracked or ing fuel tank.
To change oil and filter: worn.
Route oil drain hose and valve through hole To replace secondary fuel filter: Attach 1/2 ID hose to drain valve. Put metal
in base. See engine manual and engine container under drain, and use screwdriver
See engine manual.
maintenance label for oil/filter change in- to open sludge drain valve. Close valve
formation. Close doors. when sludge has drained. Remove hose.
D502K 5+4 TM-4412 Page 27
7-7. Servicing Engine Cooling System
1 Radiator Cap
2 RAdiator Air Bleed Screw
3 Radiator Drain Cock
2 Drain engine coolant according to

procedure in engine manual.
Add engine coolant according to
procedure in Section 4-6.
Tools Needed:
3/8 in
Ref. 803 123-A / 803 136
TM-4412 Page 28 D502K 5+4

7-8. Overload Protection
Y Stop engine.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and auxiliary power is low or
stops entirely. If F1 continues to open,
check integrated rectifier SR1, capaci-
tor C9, the rotor, and brush connec-
tions.
If F2 opens, weld output stops. 4 kVA/
kW auxiliary power is still available. If
F2 continues to open, check field cur-
rent regulator board PC1, the rotor,
and brush connections.
3 Circuit Breaker CB4 (Not Shown)
2 1 4 Circuit Breaker CB5
5 Circuit Breaker CB10 (Not
Shown)
CB4 protects the welding arc drive
7 (dig) circuit. If CB4 opens, the elec-
6 trode 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 trans-
former 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
4 8 volt output to RC14 stops. If CB5 con-
tinues to open, check remote controls
connected to RC14, and circuit board
PC6 (see Section 10-5).
CB10 protects the engine battery cir-
cuit. 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 avail-
able). 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 auxilia-
ry power output may not be available.
If CB12 continues to open, check field
current regulator board PC1 (see Sec-
tion 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 re-
mote 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
1 Engine 11 10
Supplies force to turn revolving
fields. Filter Board Circuit
PC6/Remote Breakers
2 Control Relays CR2, CR5 Receptacle RC14 CB5, CB13 9
CR2 energizes at start-up to supply
power to the fuel solenoid. LED Board PC9
CR5 energizes at start-up to supply 12 13
power to PC1. Process/ Voltage/
3 Main/Exciter Revolving Fields Contactor Switch S6 Amperage
Adjust Control 8
Turn at 1850 rpm maximum for weld Remote Electrode Switch S5
and power. The speed and excitation Hot
current of the field coils determine
voltages in stator windings. 7
4 Stator Windings Voltage/
Amperage Field
Supply power to exciter, auxiliary Current
power, and weld circuits. Adjust
Control R1 Regulator
5 Fuses F1, F2 Board
2 PC1
Protect aux. stator (exciter) windings
from overload.
Control Relay
6 Integrated Rectifier SR1 CR5
Changes ac output of stator windings
to dc to supply excitation current to
the exciter revolving field. 2
6 5 5
7 Voltage/Amperage Adjust
Control R1 Control Relay
Integrated
Adjusts voltage/amperage within CR2 Rectifier Fuse F1 Fuse F2
range selected by S3. SR1
8 Field Current Regulator Board
PC1 1 3 4
Adjust weld output by changing re- Exciter
volving filed current after comparing Revolving
Weld
feedback to voltage/amperage set- Engine Fields
(Rotor) Stator Windings
ting of R1.
9 LED Board PC9 Auxiliary Power
Monitors power, remote control,
command, engine rpm, and field ex-
citation inputs to PC1.
10 Circuit Breakers CB5, CB13
Protects PC6/RC14 from overload.
24
11 Filter Board PC6/Remote 14
Receptacle RC14 Transformer
PC6 protects unit from high frequen- T1
cy and excess voltage caused by a
damaged remote control cable.
RC14 connects remote voltage/am-
perage and contactor control to unit.
12 Process/Contactor Control
Switch S6
Selects weld process and weld out-
put on/off control (Weld Terminals Al-
ways On or Weld Terminals Remote-
ly Controlled).
25
Integrated
Rectifiers
SR4, SR5
Figure 10-1. Functional Diagram

TM-4412 Page 30 D502K 5+4
13 Voltage/Amperage Adjust Control
AC Or DC Control Circuits Switch S5
Selects Panel or Remote voltage/am-
perage control.
3φ Power 14 HF Filter Boards PC4, PC5
Protect unit from high frequency.
15 Circuit Breakers CB1 And CB2
Weld Current Circuit Protect AC receptacles RC1 and
GFCI1 from overload.
Either Mechanical Coupling 16 AC Receptacles RC1 And GFCI1
Or External Circuits
Provide connection points and power
for auxiliary equipment.
Magnetic Coupling
17 Reactor Z1
♦ Optional Tapped reactor limits weld output and
provides coarse ranges.
18 Amperage Range Switch S3
Selects coarse range of weld output
from Z1.
OCV 19 Main Rectifier SR3
Feedback Changes ac weld output to dc.
20 HF Filter Board PC3
Protects main rectifier from high fre-
quency and voltage spikes, and pro-
22♦ 22 ♦
vides OCV feedback signal to PC1.
Voltmeter Ammeter 21 Polarity/AC Selector Switch S13

V1 A2 Selects ac weld output or polarity of dc
weld output.
22 Voltmeter V1, Ammeter A1
17 18 19 Display weld voltage and current.
23 Electrode And Work Weld Output
Reactor Amperage Main Terminals
Z1 Range Rectifier
Switch S3 SR3 Provide weld output. Without optional
20 Polarity/AC Selector switch S13 termi-
nals are labeled negative (–) and posi-
HF Filter tive (+).
Board PC3 24 Transformer T1
21♦
Supplies power to arc drive (dig) circuit.
Polarity/AC Arc drive circuit only active in Stick
Selector mode.
Switch S13 25 Integrated Rectifiers SR4, SR5
Change ac output of stator windings to
15 dc to supply power to arc drive (dig)
circuit.
Circuit Breakers
CB1, CB2
14
HF Filter 14 14
Board PC4
16
HF Filter HF Filter
AC Board PC4 Board PC5
Receptacles
RC1, GFCI1
23 23
Electrode Work
Weld Output Weld Output
Terminal Terminal
Electrode Work
D502K 5+4 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 FUNCTION PICTURE CIRCUIT SYMBOL
CAPACITOR A device that stores electrical energy. Large

POLARIZED NON-POL.
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk” C1 C1
capacitors can be used for HF protection.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse CB1
that needs to be replaced when blown, a
circuit breaker can be reset.
DIODE A device that allows current to flow in one

direction only. Most common use is to D1
change AC to DC.
FUSE A protection device, usually an enclosed

piece of wire that melts and breaks the circuit F1
when the current exceeds the fuse rating.
HALL DEVICE Produces a small DC voltage proportional to

the current it is sensing (usually welding HD1
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
RESISTOR A device which resists the flow of electric FIXED R1

current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED TAPPED R1
POTENTIOMETER Both devices have a moveable brush that

OR makes contact along a resistor, allowing you
RHEOSTAT to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator VARIABLE R1
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
TM-4412 Page 32 D502K 5+4

FAN MOTOR 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; VR1
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 These are electromechanical devices used to

SOLENOID start or stop the flow of shielding gas or
(VALVE) water. GS1
OR
WS1
RELAY––COIL AND This is an electromechanical device whose COIL

CONTACTS, contacts change state (the normally open
NORMALLY OPEN points close and the normally closed points
AND NORMALLY open) when proper voltage is applied to the
CLOSED coil. These contact points in turn may control CR1 CR1
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show NRM OPEN NRM CLOSED
the contact points in the power off state. POINTS POINTS
THERMOSTAT, This is a switch that closes its normally open

NORMALLY OPEN contacts (or opens its normally closed
AND NORMALLY contacts) when a preset temperature is TP1 TP1
CLOSED reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when NRM OPEN NRM CLOSED
needed and shutting off the output of a
welding power source if it is overheating.
CONTACTOR A heavy duty relay. Usually used to make

and break the welding arc or primary power. COIL
W
W
NRM OPEN
POINTS
PILOT LIGHT A light located on the front panel which

1
indicates if the machine is on or off.
PL
STABILIZER/ When placed in a DC circuit, the inductor or

REACTOR stabilizer as it is usually called, will oppose
any change in existing current. It is therefore Z1
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 L1
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
D502K 5+4 TM-4412 Page 33

MOTOR A device that is typically used to feed wire in

a MIG welding system.
B1
SHUNT A precision low-value resistor typically used

to supply a small voltage to drive an
SHUNT
ammeter.
MOSFET A device that is used as an “electronic D

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
G
to control a relay, the speed of a motor, or
even the output of a welding machine. AS
S
IGBT A device that is used as an “electronic

switch.” When a signal is applied to the gate C1
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically G1 (B1)
used in “Invertor” designed welding machines
to control the welding output. E1
BRUSHES/SLIP Components that allow electrical connections

RINGS between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
TERMINAL STRIP An insulated connection point for wires. They

are used for the ease of making multiple
connections and can be a convenient point 42 42 104 105 74
1T
for making electrical checks when A B C D E
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
SWITCH A mechanical device that completes or SPST SPDT

breaks the path of the current or sends it over
a different path.
DPST DPDT
TM-4412 Page 34 D502K 5+4

SCR A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current K
G
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 A
control the output to a load such as a welding
arc.
THERMISTOR A thermally sensitive resistor. The resistance

RT1
of a thermistor changes with a change in
temperature. Primarily used for “Fan on OR
Demand” and “Thermal Shutdown” circuits. TH1
TRANSFORMER A device that changes AC voltage from one

magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
T1
INTEGRATED An arrangement of four diodes used to AC +

BRIDGE change AC to DC. AC
RECTIFIER +
–
AC _ AC
SPARK GAP The arrangement of two electrodes between

which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding. G
CURRENT A transformer that produces an AC voltage CT1

TRANSFORMER used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in OR
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current. CT1
D502K 5+4 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 neces-
sary.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
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.
Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Erratic weld output. Use dry, properly stored electrodes.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Check and tighten connections inside and outside unit.
Check main rectifier SR3, and replace if necessary.
TM-4412 Page 36 D502K 5+4

Trouble Remedy
High weld output. Check position of Amperage Range switch S3 and Voltage/Amperage Adjust control R1.
Check engine speed, and adjust if necessary (see Section 7-5).
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).
10-7).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
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.
Repair or replace remote control device.
Wire feeder does not work with welding Reset circuit breaker CB5 or CB6 (see Section 7-8).
generator.
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.
10-7).
Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit. Feed-
back voltage should be the same as weld terminal open circuit voltage (see Section 10-2).
B. Auxiliary Power
Trouble Remedy
No auxiliary power output; weld output Reset receptacle circuit breakers.
okay.
Check resistance of auxiliary power windings between leads 81 and 84. Replace exciter stator (aux. sta-
tor) 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.
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.
10-7).
High output at auxiliary power Check engine speed, and adjust if necessary (see Section 7-5).
receptacles.
Low output at auxiliary power Check engine speed, and adjust if necessary (see Section 7-5).
receptacles.
Check fuse F1, and replace if open (see Section 7-8).
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 7-8).
Check engine wiring harness and components.
Check engine wiring harness plug connections.
Check continuity of Engine Start/Preheat switch S1, and replace if necessary.
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR2 if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coils. Replace
FS1 if necessary.
Check fuel pump (see engine manual).
Air in fuel system. See engine manual.
TM-4412 Page 38 D502K 5+4

Trouble Remedy
Engine starts, but stops when Start/Pre- Check coolant level. Automatic shutdown system stops engine if engine temperature is too high (see Sec-
heat switch S1 is released. tions 4-5).
Check timer relay T for proper coil voltage and connections. Check continuity of coil and condition of con-
tacts. Replace timer relay T 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 Sec-
tions 4-5).
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coils. Replace
FS1 if necessary.
Engine slowly stopped and cannot be Check fuel level.

restarted.
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
V18 I2
V19
I1
See Section
4-9 for RC14 V6, R6
information V17
V20
V21
V14,
R12
V16 V15
R13
Timer
Relay T
TM-4412 Page 40 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 Engine temp.

latching latching relay
relay CR1 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
c) Reference – single arrow: reference
to circuit common (lead 42); double
arrow: reference to points indicated
Resistance Values
d) Process/Contactor Control switch S6
in Weld Terminals Always On – CC a) Tolerance – ±10% unless
Stick position unless noted specified
e) Wiring Connections – see Section 12 b) Condition – 70°F (21°C); cold
machine (no warm-up)
V1 126 – 130 volts ac
V2 126 – 130 volts ac c) Wiring Connections – see
Section 12
V3 252 – 260 volts ac
V4 27 volts ac
d) Stop engine before checking
resistance
V5 101 volts ac
V6 175 volts ac R1 thru R6 Less than 1 ohm
R7 18.5 ohms
V7 +135 volts dc
R8 14.2 ohms
V8 + 89 volts dc
R9 thru R11 Less than 1 ohm
V9 +89 volts dc (S6 in Weld Terminals Always R12 15 ohms
On –Stick position)
R13 Less than 1 ohm
+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.) Amperage Readings
V12 69 volts ac (R1 at max.) a) Tolerance – ±5% unless specified
V13 +89 volts dc (S6 in Weld Terminals Always b) Condition – 70°F (21°C); cold
On – Stick position)
47 volts dc (S6 in Weld Terminals Always
machine (no warm-up); no load
On – Scratch Start Tig position) c) Process/Contactor Control
+16 to 56 volts dc from min to max of R1 switch S6 in Weld Terminals
(S6 in Weld Terminals Always On – MIG Always On – CC Stick position
position)
unless noted
V14, +12 volts dc with Start/Preheat switch S1 in
V15, Preheat position I1 6.3 amps dc
V16
I2 4.3 – 4.6 amps dc
V17 0 to +10 volts dc from min to max of R1
V18 +12 volts dc
V19 0 to +10 volts dc from min to max of R1
V20 +12 volts dc
V21 +12 volts dc
V22 258 volts ac with Process/Contactor
Controlswitch S6 in Stick position
V23, 18 volts ac with Process/Contactor
V24 Control switch S6 in Stick position
TM-4412 Page 42 D502K 5+4

10-4. Waveforms For Section 10-2
1 ms 10 V
1 ms 50 V
gnd
gnd
A. DC/CC Open-Circuit Voltage, Voltage/ B. DC/CC Output, 28 Volts DC, 200 Amperes,
Amperage Adjust Control R1 At Maximum Amperage Range Switch S3 At 125-400
Position (Resistive Load)
D502K 5+4 TM-4412 Page 43

10-5. Filter Board PC6 Testing Information
Y Stop engine.
See Section 10-6 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
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
PC6 Voltage Readings
(lead 42) unless noted
c) Condition – no load
d) Process/Contactor Control switch
S6 in Weld Terminals Always On –
CC Stick position
Receptacle Pin Value
RC2 1 Not used
2 115 volt ac input with respect to pin RC2-10
3 24 volt ac input with respect to pin RC2-10
4 24 volt ac output with respect to pin RC2-10
5 Contactor control circuit, 24 volt ac input with contact closure to pin RC2-9 and closure on RC14 be-
tween pins A and B or pins I and J
6 Command reference, 10 volt dc input
7 Command common
8 Remote command signal output, 0 to +10 volts dc input from min to max of remote voltage/amperage
control
9 Circuit common for 24 and 115 volt ac contactor control circuits
10 Circuit common for 24 and 115 volt ac circuits
D502K 5+4 TM-4412 Page 45

10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9
Determine the condition of field cur-

rent regulator board PC1 by ob-
serving 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 Sec-
tion 10-8 for diagnostic information
and specific values during testing.
1 Field Current Regulator Board
PC1 Module
2 LED Board PC9
3 Diagnostic LED’s (See Sec-
tion 10-8)
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 Con-
trol switch S5 in Panel position
b) Reference – to circuit common
LED Status Self-Test
POWER On Indicates +12 volts dc is present to energize PC1.
Off If LED is off:

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 Indicates 24 volts ac input with Process/Contactor Control switch S6 in Weld Terminals Always On posi-
ON/OFF tion, or with S6 in a Weld Terminals Remotely Controlled position with remote contactor closed.
Off If LED is off:

Place Process/Contactor Control switch S6 in Weld Terminals Always On position, or place S6 in Weld
Terminals Remotely Controlled position and connect remote contactor to remote receptacle RC14.
Reset circuit breaker CB5.
Check filter board PC6 and connections, and replace if necessary (see Section 10-5).
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 On Indicates engine speed is less than 1704 rpm (approximately).

LIMIT
If LED is on:
. LED normally And AC Input LED is on, check engine weld/power speed and adjust if necessary.
off at weld/
And AC Input LED is off, check fuse F2, and replace if open.
power speed)
And AC Input LED is off, reset circuit breaker CB12.
Off Indicates engine speed is above 1704 rpm (normal operation).
AC INPUT On Indicates + 175 volts ac input from field excitation circuit.
Dim or Off If LED is off, power LED is on, and normal ac voltage is present at ac receptacles (see Section 10-2):
Check fuse F2, and replace if open.
Reset circuit breaker CB12.
D502K 5+4 TM-4412 Page 47

10-9. LED Board PC9 Testing
Be sure plugs are secure. See Sec-

tion 10-10 for specific values during
testing.
1 LED Board PC9
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
PC9 Voltage Readings b) Reference – to circuit common
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 Value

PLG13 1 Power LED, +2 volts dc input
To test power LED, apply +2 volts dc to PLG13-1 and connect negative (–) side of power supply to
PLG13-8. LED lights if okay.
2 Not used
3 Not used
4 Not used
5 AC input LED, +1.85 volts dc input with respect to pin PLG13-10 when weld exciter voltage is
present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (–) side of power sup-
ply to PLG13-5. LED lights if okay.
6 Output on/off LED, 0.13 volts dc input with contactor off; + 2 volts dc input with contactor on.
To test output on/off LED, apply +2 volts dc to PLG13-6 and connect negative (–) side of power sup-
7 Command LED, 0 to 2 volts dc input from min to max of Voltage/Amperage Adjust control R1.
To test command LED, apply +2 volts dc to PLG13-7 and connect negative (–) side of power supply
to PLG13-8. LED lights if okay.
8 Circuit common
9 RPM Limit LED, +10.5 volts dc input at 1850 rpm; voltage decreases as engine speed decreases.
LED goes on when engine speed is less than 1704 rpm (approximately).
To test rpm limit LED, apply +2 volts dc to PLG13-8 and connect negative (–) side of power supply to
PLG13-9. LED lights if okay.
10 AC Input LED, +1.85 volts dc input with respect to pin PLG13-5 when weld exciter voltage is present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (–) side of power sup-
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 re-
move clip and brush from brush
holder assembly. Remove and in-
spect 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.
3
4
Minimum Length: 2
5/8 in (16 mm)
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 nec-
essary (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
1 R3 connections until correct volt-
age is obtained at receptacles with-
out exceeding 4.6 amperes dc ex-
citer revolving field current (see
Section 10-2).
Check open-circuit voltage across
weld output terminals. There
should be 90 volts dc present. If
correct voltages are not present, re-
Y Stop engine before adjusting resistor R3. peat troubleshooting procedures in
Section 10-1.
Y Stop engine.
Allow engine to cool, and then com-
plete pre-operational checks in
2 table.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.

Test Equipment Needed: Tools Needed:
Check fuel and oil (see Section 4-5).
Check and correct any fluid leaks.

Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
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. Dis-
connect battery negative (–)
cable.
Remove exhaust pipe, fuel cap, and
top cover. Reinstall fuel cap. Remove
side panels and door(s). Retain all
hardware.
1 Control Box
Disconnect plugs from control box.
Remove box.
. To aid in reassembly, mark leads

before disconnecting. See lead
list summary in Section 12 for
connection information.
Disconnect:
F stator weld leads from Amper-
age Range switch S3
F stator exciter leads from termi-
nal strip 1T
1 F resistor R3 leads
F weld output terminal leads
3
2 2 Front And Center Upright
Assembly
3 Reactor Z1 Lifting Eye
The entire assembly will be removed
together. Remove bolts securing up-
rights to base. While supporting as-
sembly at front panel and reactor lift-
ing eye, evenly lift and remove
assembly.
4 Engine
4 5 Flywheel Housing
6 Front Generator Mounts
Support engine under flywheel hous-
ing with a 1 x 3 x 30 in (25 x 76 x 762
mm) metal bar.
. Do not support engine on fuel

tank or under oil pan.
Remove front generator mounts. Go
to Section 11-2.
6
802 431-C
TM-4412 Page 52 D502K 5+4

11-2. Disassembly Of Generator
A
4
E
1
2
C
D B
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 win- Exciter stator comes off with endbell. Reinstall upright assembly. Reconnect fuel
dings during this procedure. line.
4 Rotor
1 Stator Reconnect all leads. Use cable ties to secure
If engine must also be removed, remove en-
leads in existing wiring harness and away
With engine properly supported with metal gine from base mounts.
from moving and hot parts.
bar (see Section 11-1), remove hardware se-
Reassembly Instructions:
curing stator to engine. Remove the following Reconnect negative (–) battery cable. Rein-
parts as needed: Reinstall engine and generator parts as stall panels, door, and exhaust pipe.
needed using torque values in table.
2 Endbell
3 Exciter Stator
D502K 5+4 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:
Circuit Wiring
Model Serial Or Style Number
Diagram Diagram
D502K 5+4 LC110463 and following 206 628-A See Table 12-1
Circuit Board PC4, PC5 LC110463 and following 189 746

(HF Filter)
Circuit Board PC3 LC110463 and following 188 607

(HF Filter)
Circuit Board PC6 LC110463 and following 192 997

(HF Filter )
Circuit Board PC9 LC110463 and following 192 227-A

(LED)
D502K 5+4 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
R1
RV1
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 RC6 (2) – S3 (2)
––––H RC6 (1) – S3 (1) 0042AB BASE GROUND TO D10 (–)
0010A T1 SEC TO SR4 (AC) 0042AC CR5 (85) TO D10 (–)
0011A STATOR TO EXIT 0042AD FUEL SENDER TO BASE GROUND
0012A #1 COIL TO RANGE SWITCH 0042AE GROUND CABLE TO OIL PRESSURE SWITCH
0013A #1 COIL TO RANGE SWITCH 0042AF FUEL PUMP TO FUEL SENDER
0014A #1 COIL TO RANGE SWITCH 0042BA SPLICE A TO SPLICE B
0015A #1 COIL TO RANGE SWITCH 0042BB SPLICE TO D10 (NEG)
0016A #1 COIL TO RANGE SWITCH 0042CC RC3 (2) TO LEAD 42JJ
0017A #1 COIL TO RECTIFIER 0042DD SPLICE TO TIMER (NEG)
0017A PC3 TO BUS BAR 0042EE SPLICE TO HOUR MTER (NEG)
0018A T1 SEC TO SR4 (AC) 0042H PC1 (PLG8–F3) TO PC8 (PLG13–8)
0019A PC3 TO HEAT SINK (+) 0042JJ SPLICE TO LEAD 42 CC
0019B PC3 TO LEAD 19 FROM PC1 (E2) 0042K PC1 (PLG8–C1) TO PLG3 (2)
0019C PC3 TO LEAD 19 FROM VOLTMETER (+) 0042KK SPLICE TO LEAD 42 SS
0019D SR3 (+) TO WELD TERMINAL (+) 0042L END BELL (BOTTOM–LEFT) – PC4 (GND)
0019E SR4 (+) TO SR3 (+) 0042L END BELL (BOTTOM–RIGHT) – PC5 (GND)
0019F SR5 (+) TO SR3 (+) 0042L END BELL (TOP–LEFT) – PC6(GND)
0019J PC1 (PLG8–E2) TO LEAD 19 FROM PC3 0042M ASSY TO TEMP GAUGE (5)
0021A STATOR TO EXIT 0042N GND STD (BASE) TO GND STUD (AUX PANEL)
0022A #2 COIL TO RANGE SWITCH 0042P 1T (C–RIGHT) – GND STUD
0023A #2 COIL TO RANGE SWITCH 0042R GFCI (GND) – GND STUD
0024A #2 COIL TO RANGE SWITCH 0042S RC1 (GND) – GND STUD
0025A #2 COIL TO RANGE SWITCH 0042SS SPLICE TO 42KK
0026A #2 COIL TO RANGE SWITCH 0042T 076 (K) TO LEAD 42 FROM END BELL
0027A #2 COIL TO RECTIFIER 0042U ASSY TO HOUR METER (–)
0027A PC3 TO BUS BAR 0042V ASSY TO FUEL GAUGE (5)
0030A PC3 TO HEAT SINK (–) 0043A START SWITCH (17) TO GLOW PLUGS
0030B PC3 TO LEAD 30 FROM PC1 (E1) 0043B START SWITCH JUMPER #17 TO #19
0030C PC3 TO LEAD 30 FROM VOLTMETER (–) 0043D S1 (19) TO D9 (–)
0030D SHUNT (OUTSIDE) TO LEAD 30 FROM 0043E GLOW PLUG TO FS1 (PULL)
AMMETER 0044A CR5 (87A) TO CB10 (SILVER)
0030E SHUNT (INSIDE) TO LEAD 30 FROM AMMETER 0044B CB10 (SILVER) TO START SW (30)
0030F SR3 (–) TO WELD TERMINAL (–) 0044C CB10 (SILVER) TO ALT (B)
0030G SR4 (–) TO SR3 (–) 0044H CR5 (87) TO TIMER (N.O.)
0030H SR5 (–) TO SR3 (–) 0044J CB10 (SILVER) TO CR1 (30)
0030J PC1 (PLG8–E1) TO LEAD 30 FROM PC3 0045A CR2 (30) TO FS1
0031A STATOR TO EXIT 0046A STOP SW (CENTER) TO CR 2 (87A)
0032A #3 COIL TO RANGE SWITCH 0048A LEAD 48B TO S6 (9)
0033A #3 COIL TO RANGE SWITCH 0054A CT2 TO CT1
0034A #3 COIL TO RANGE SWITCH 0055A CT2 TO CT1
0035A #3 COIL TO RANGE SWITCH 0060A D8 (POS) TO ALT (IND)
0036A #3 COIL TO RANGE SWITCH 0061A D10 (+) TO CR1 (86)
0036A PC8 (PLG1–G1) TO PLG6 (3) 0061B D8 (–) TO D9 (+)
0036C RC6 (3) – S3 (3) 0061C SPLICE TO HOUR METER (+)
0037A #3 COIL TO RECTIFIER 0061CA D9 (+) TO D10 (+)
0037A PC1 (PLG8–G2) TO LEAD 37 FROM SR3 0061D SPLICE TO FUEL GAUGE (6)
0037A PC3 TO BUS BAR 0061E D8 (–) TO CR5 (86)
0037B PC3 TO LEAD 37 FROM PLG3 (2) 0061F TIMER (+) TO STOP SW (BOTTOM)
0038A T1 SEC TO SR5 (AC) 0061H SPLICE TO TEMP GAUGE (6)
0039A T1 SEC TO SR5 (AC) 0061J SPLICE TO TEMP GAUGE (2)
0040A STARTER TO AMP METER (POS) 0061K FUEL PUMP TO CR1 (87A)
0041A AMP METER (NEG) TO CB10 (COPPER)
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 TIMER (C) TO D8 (NEG) 0104B RC1 (6) TO F2
0061N D8 (–) TO CR2 (86) 0105A BRUSH (CENTER) – PLG1 (2)
0061P TIMER (POS) TO TIMER ”C” (COMMON) 0105B SR1 (+) TO C9
0061Q STOP SW BOTTOM TO HOUR METER (POS) 0105D RC3 (8) TO C9 (+)
0061R CR1 (87) TO D10 (POS) 0105E PC1 (PLG8–D1) TO PLG3 (8)
0062A TEMP GAUGE (4) TO CR2 (85) 0105F RC1 (2) TO SR1 (+)
0064A STARTER SOLENOID TO START SW (50) 0106A BRUSH (FRONT) – PLG1 (5)
0066B LEAD FROM CT1 TO PC7 (D) 0106B RC1 (5) TO SPLICE
0067B LEAD FROM CT1 TO PC7 (G) 0106C RC3 (7) TO SPLICE
0068B S6 (10) TO CR6 (30) 0106D CR4 (6) TO SPLICE
0069A CR1 (85) TO OIL SENDER (S12) 0106D R3 TO PLG3 (7)
0070A COOLENT SENDER TO TEMP GAUGE (3) 0106E SPLICE (A) TO SPLICE (B)
0071A FUEL GAUGE (3) TO FUEL SENDER 0108A BRUSH (REAR) – PLG1 (8)
0081A EXCITER STATOR – 1T (A–LEFT) 0108B RC1 (8) TO RC3 (9)
0081B CB1 (BOTTOM) – 1T (A–RIGHT) 0108C PC1 (PLG8–A2) TO PLG3 (9)
0081D EXCITER TO T1 0110A CB12 TO RC3 (11)
0081E T1 PRI TO EXCITER STATOR 0110B PC1 (PLG8–C2) TO PLG3 (11)
0082A EXCITER STATOR – 1T (B–LEFT) 0111A CB12 TO CB11
0082B GFCI (N) – 1T (B–RIGHT) 0111B CB12 TO CR5 (30)
0083A EXCITER STATOR – 1T (C–LEFT) 0113A CB11 TO RC3 (12)
0083B PC6 (PLG14–10) TO (1T–83C) 0113B PC1 (PLG8–B1) TO PLG3 (12)
0083D PC6 (PLG14–9) TO PC1 (PLG9–F2) 0116A PC6 (PLG14–8) TO PC1 (PLG9–B1)
0084A EXCITER STATOR – 1T (D–LEFT) 0117A PC6 (PLG14–7) TO PC1 (PLG9–C3)
0084B CB1 (BOTTOM) – 1T (D–RIGHT) 0118A PC6 (PLG14–6) TO PC1 (PLG9–B2)
0084D EXCITER TO S6 0119A S6 (1) TO PC6 (PLG14–5)
0084E AUX STATOR TO S6 (11) 0120A S6 (2) TO PC1 (PLG9–F1)
0084F 1TD TO CB23 0121A S6 (3) TO PC6 (PLG14–4)
0085A CB2 (BOTTOM) – GFCI (HOT) 0121B PC6 (PLG14–3) TO CB5
0085B CB2 (BOTTOM) – PC4 (5) 0122A PC1 (PLG9–A1) TO S6 (5)
0086A CB1 (TOP) – RC1 (BOTTOM–RIGHT) 0123A PC1 (PLG9–A2) TO S6 (6)
0086D CB1 (TOP) – CB2 (TOP) 0124A S6 (7) TO PC1 (PLG9–D3)
0087AA CB23 TO PLG14 (2) 0125A PC1 (PLG8–F1) TO PLG6 (1)
0088A CB1 (TOP) – RC1 (BOTTOM–LEFT) 0126A PC1 (PLG8–F2) TO PLG6 (2)
0088B CB1 (TOP) – PC4 (4) 0127A S5 (TOP) TO PC1 (PLG9–B3)
0089A EXCITER TO CB5 (TOP) 0128A S5 (CENTER) TO PC1 (PLG9–D2)
0098A S6 (12) TO CB4 0129A S5 (BOTTOM) TO PC1 (PLG9–2)
0099A T1 PRI TO CB4 0134A R1 (PLG10–1) TO PC1 (PLG9–D1)
0100A EXCITER STATOR – PLG1 (1) 0135A R1 (PLG10–2) TO PC1 (PLG9–C1)
0100B RC1 (1) TO F1 0136A R1 (PLG10–3) TO PC1 (PLG9–A3)
0101A EXCITER STATOR – PLG1 (3) 0137A SR1 (AC) TO F1
0101B RC1 (3) TO SR1 (AC) 0138A RC3 (1) TO F2
0102C SR1 (–) TO C9 (–) 0138B PC1 (PLG8–A3) TO PLG3 (1)
0102D RC3 (4) TO C9 (–) 0139A PC1 (PLG8–C3) TO PC8 (PLG13–1)
0102E R3 TO PLG3 (4) 0140A PC1 (PLG8–D2) TO PC8 (PLG13–5)
0103A EXCITER STATOR – PLG1 (4) 0141A PC1 (PLG8–D3) TO PC8 (PLG13–6)
0103B PC1 (PLG8–A1) TO PLG3 (6) 0142A PC1 (PLG8–K2) TO PC8 (PLG13–7)
0103D RC3 (6) TO RC1 (4) 0143A PC1 (PLG8–J2) TO PC8 (PLG13–9)
0104A EXCITER STATOR – PLG1 (6) 0144A 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 equip-
ment damage may occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
. Do not idle engine longer than

necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
1 run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al 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
4
from flammables.
2 procedure at less than 20
1 exceed duty cycle or equip-
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum 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 dur-

ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
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
6
from flammables.
2 procedure at less than 20
exceed duty cycle or equip-
1 Resistance Grid
Use grid sized for generator rated
output.
1 Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum 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 connec-
tors (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, rat-
4 ing label, or the specifications sec-
tion in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
+ loaded properly.
. Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
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 87
18 84
12
88
19
3 11
4 6
5 9
89
10
8
90
7
91
111
92
112
93
110
12
94 95
109 (Fig. 14-5)
103
102
96
104
101 (FIG. 14-2) 91
108 97
98
99
100
106 105
107 (FIG. 14-3)
Figure 14-1. Main Assembly

TM-4412 Page 66 D502K 5+4
39
36
37
26
38
27
25 40
33
22
24 35
21 23 42
34 43
30
31
20 32
30
41
44
29 45
28
81
78
77 79
76
80
75
74
73
60 56
59
6261
31 58
57 49
63 48
64 46
70 65 47
71 66
50
67
72 (Fig 14-4) 68 57
51
69
53
52
55
54
803 201
D502K 5+4 TM-4412 Page 67

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 14-1. Main Assembly
. . . 1 . . . . . . . . . . . . . +199294 . . Panel, Gen Lh Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . +199301 . . Panel, Engine Side Stainless Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . Z1 . . . . . 202647 . . Reactor, AC Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . 1T . . . . . 038621 . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 081499 . . Bracket, Mtg Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40 Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 201697 . . Pan, Reactor & rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . . 205636 . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 173352 . . Extrusion, Rubber Clamp/Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 ft
. . . 13 . . . . . . . . . . . . . . 189708 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 200968 . . Hose, Elbow Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206393 . . Pipe, Air Cleaner Intake Kubota V3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦192939 . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 206351 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . +206541 . . Cover, Top Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw–on 3.500 In W/Vent W/Lanyard (included w/tank) . . . . 1
. . . 23 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 202629 . . Cover, Radiator Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 202633 . . Support, Cover E–coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 6
. . . 31 . . . . . . . . . . . . . . 206388 . . Guard, Fan (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 206517 . . Radiator, W/Shroud & 7# Cap 4row Core Assy Rda (consisting of) . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206518 . . . . Radiator, Big Blue Air Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 605982 . . . . Cap, Radiator Pressure 7 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206384 . . . . Shroud, Radiator Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 207192 . . Panel, Engine Extension L.h. Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 207005 . . Grill, Rear Panel Stainless Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 207188 . . Upright, Rear Radiator Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . . 203430 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . BATT . . . . 190896 . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Low Mainte (Dry) . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312–18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . . +202639 . . Cover, Battery Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 207193 . . Panel, Engine Extension R.h. Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 206387 . . Guard, Fan (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 206604 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 190126 . . Latch, Paddle Series 20 (Ss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 206999 . . Label, Maintenance D502k 5+4 Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 199338 . . Door, Engine Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4412 Page 68 D502K 5+4

Item Dia. Part
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
Item Dia. Part
Figure 14-1. Main Assembly (Continued)
. . 100 . . . . R3 . . . . . 189699 .. Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1

. . 101 . . . . . . . . . Figure 14-2 .. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 191512 .. Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 189731 .. Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 199305 .. Cover, Top Front Upright Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 202637 .. Upright, Front Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 200910 .. Label, Warning Electric Shock And Moving Parts CE . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . Figure 14-3 .. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . . . . . . ♦ .. Transformer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . SR3 Figure 14-5 .. Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 193453 .. Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . PC1 . . . . 207397 .. Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . . 203260 .. Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191819 .. Hose, Sae .312 Id X .560 Od X 14.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 095636 .. Hose, Sae .187 Id X .410 Od X 30.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 198584 .. Hose, Sae .312 Id X .560 Od X 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 .. Nut, 312–18 U–nut Multi–thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . 190058 .. Nut, 250–20 U–nut Multi–thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 206993 .. Kit, Label (Includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206 993.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
13
12
3
5
16
15
2
1 11
9
10
7
6
14 803 203
Figure 14-2. Control Box Assembly

TM-4412 Page 70 D502K 5+4
Item Dia. Part
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
. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 201077 . . . Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3
. . . 7 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box,Weld Control L.h. (consisting of) . . . . . . . . . . . . . . . 1
. . . 10 . . CB11, CB12 . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . SR1 . . . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 12 . . CR1, CR5 . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . CR2 . . . . 173069 . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . T . . . . . . 207139 . . Timer, Delay On Make/Break Open 3–60 Sec 12vdc . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206398 . . Harness, Engine Kubota V3300 (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S7 . . . . . 199691 . . . . Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (located on
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . front panel, see Figure 14-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . D8/C8 . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D9/C9
D10/C10
D502K 5+4 TM-4412 Page 71

3
4
5
6
8
1 9 7
45 10
44
11
43 12
13
14
15
42
41
40 33 16
39
36 35
38 33
37
32 19
34
31
30 17
20 18
21
22
29
23
28
27 26 25 24 803 202
Figure 14-3. Panel, Front w/Components

Item Dia. Part
Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 107)
... 1 .............. 206212 . . Plate, Screened Ident Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 206382 . . Panel, Engine/Weld Control Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 192558 . . Harness, Range Switch (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Conn,Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . 4 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4412 Page 72 D502K 5+4

Item Dia. Part
Figure 14-3. Panel, Front w/Components (Continued)
. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . RC10 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB13 . . . . 139266 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . . 207720 . . Switch, Ignition 3 Position (Mom–off–mom) W/Handle . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S7 . . . . . 199691 . . Switch, Tgl Spdt 6a 125vac On–none–mc Spd Term (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine harness, see Figure 14-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . GFCI-1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5–20r Gfi . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . . 147632 . . . . Rcpt, Tw Lk Grd 2p3w 30a 250v *L6–30r . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts CE . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . +202641 . . Panel, Auxiliary Power Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 601836 . . Nut, 250–20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250–20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦196073 . . Label, Do Not Switch While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . . ♦ . . Switch, Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 199303 . . Panel, Mtg Terminal Power Output Stainless . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . PC4, PC5 . . 189744 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . NEGATIVE . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8
. . . 26 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . . . . . . ♦ . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . . . . . ♦ . . Pin, Spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . POSITIVE . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 193260 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 193258 . . Cover, Receptacle Gfci Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 34 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . HM . . . . . 118058 . . Meter, Hour 12–24vdc 2.25 Dia High Profile Stainles . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . AM . . . . . 118060 . . Meter, Amp Dc 60–0–60 2.250 Dia High Profile Stainl . . . . . . . . . . . . . . . . 1
. . . 39 . . . . TEMP . . . 193229 . . Gauge, Coolant Temp 0– 300 Deg F Electric Switch . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . ♦ . . Meter, Weld Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . ♦ . . Meter, Weld Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1
D502K 5+4 TM-4412 Page 73

Item Dia. Part
Figure 14-3. Panel, Front w/Components (Continued)
.................... 193158 . . Harness, Unit Weld Control – CV (consisting of) . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
.................... 088731 . . . . Bushing, Snap–in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
.................... 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 2
.................... 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 196602 . . . . Plug, Cavity 18, 30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . 10
.................... 024103 . . Blank, Snap–in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 120304 . . Blank, Snap–in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
20
17
13 18 19
16
21
15
12 14 22
9
10
11
23
8 24
7
6
5 25
3
4 18
2 28 26
29 27
30
31
32
1 33
34
29
35
803 204-A
Figure 14-4. Generator
TM-4412 Page 74 D502K 5+4

Item Dia. Part
Figure 14-4. Generator (Figure 14-1 Item 72)
. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Conical Spring .406 Id X .875 Od Pltd . . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-ring, 2.859 Id X .139cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . WELD STATOR +208287 . . Stator, Weld Assembly Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 013367 . . Label, Warning Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 191580 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 208216 . . Spacer, Stl Kubota V3300 18ga Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 039207 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . REV FLD . . . 202452 . . Rotor, Gen (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 195547 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 049026 . . Screw, M10-1.5 X 25hexhd Pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 18 . . . . . . . . . . . . . . 083883 . . Washer, Lock .042 Id X 0.709 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 19 . . . . . . . . . . . . . . 202302 . . Plate, Flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 206380 . . Adapter, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 605231 . . Screw, M10-1.5 X 35hexhd Pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . . . . . . . . . . 194512 . . Washer, Flat 1.250 Od X .406 Id X 7 Ga Thk Stal Pld . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380 Id X .860od X .109t Stl Pld 4000lbs . . . . . . . . . . . . . . 4
. . . 24 . . . . . . . . . . . . . . 198631 . . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 25 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . 172555 . . Screw, M10-1.5 X 50hexhd Pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 27 . . . . . . . . . . . . . . 602159 . . Screw, .312-18 X .75hexwhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 604950 . . Screw, .312-18 X 2.25hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318 Id X 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 31 . . . . . . . . . . . . . *190823 . . Brush, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 32 . . . . . . . . . . . . . . 188560 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . . . . . . . . . . . 189142 . . Brushholder Assembly, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . 604534 . . Screw, 312–18x1.25 Hex Hd–pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 190259 . . Harness, Brush (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 168071 . . . . Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187651 . . . . Seal, Wire Univ 9p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
D502K 5+4 TM-4412 Page 75

. Hardware is common and 4
3
802 279-A
Figure 14-5. Main Rectifier Assembly
Item Dia. Part

Figure 14-5. Main Rectifier Assembly (Figure 14-1 Item 109)
. . . . . . . . . . SR3 . . . . 208279 . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 188137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 188517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 .............. 188135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 134201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 201449 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 188136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 7 .............. 188493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 208334 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 208335 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Base Group
TM-4412 Page 76 D502K 5+4
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Contact the Delivering Carrier for: 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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TM-4412 March 2002

Eff. w/Serial Number LC110463

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting

Engine Driven Welding Generator

SECTION 11 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.

MOVING PARTS can cause injury.

D502K 5+4 TM-4412 Page 1

1-3. EMF Information

TM-4412 Page 2 D502K 5+4

2-1. Symbols And Definitions

Fast (Run, Weld/

Check Injectors/ Check Valve Protective Earth

Stick (SMAW) Constant Current MIG (GMAW)

Read Operator’s Do Not Switch

D502K 5+4 TM-4412 Page 3

CC/DC 20 – 600 A 500 A, 40 Volts DC, 95 Standard: Kubota V3300-B

3-2. Dimensions, Weights, And Operating Angles

28-1/2 in (724 mm)

* With mounting brackets in center F

TM-4412 Page 4 D502K 5+4

D502K 5+4 TM-4412 Page 5

3-5. Duty Cycle And Overheating

TM-4412 Page 6 D502K 5+4

3-7. Manufacturer’s Rating Label

D502K 5+4 TM-4412 Page 7

Movement Airflow Clearance Location

Grounding Y Always securely fasten weld-

4-2. Installing Exhaust Pipe

. Point exhaust pipe in desired di-

TM-4412 Page 8 D502K 5+4

9/16 in 803 122 / Ref. 802 169-B

4-4. Connecting The Battery

Y Connect Negative (–) Cable Last.

D502K 5+4 TM-4412 Page 9

Remove air bleed screw Check radiator coolant

TM-4412 Page 10 D502K 5+4

. Check coolant level according

803 123-A / 206 580

D502K 5+4 TM-4412 Page 11

TM-4412 Page 12 D502K 5+4

2 ea. 2/0 2 ea. 2/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

D502K 5+4 TM-4412 Page 13

Socket* Socket Information

A 24 volts ac. Protected by circuit

C Output to remote control:+10

D Remote control circuit common.

115 volts, 10 amperes, 60 Hz

Contact closure to I completes

NEUTRAL G Circuit common for 24 and 115