Red-D-Arc D502K 5+4 User manual

TM-4412 March 2002
Eff. w/Serial Number LC110463
Processes
Description
Air Carbon Arc (CAC-A) Cutting
and Gouging
Stick (SMAW) Welding
Engine Driven Welding Generator
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-4412 Page 1D502K 5+4
SECTION 1 –SAFETY PRECAUTIONS FOR SERVICING
safety_rtm 7/99 / OM-4412
1-1. Symbol Usage
MeansWarning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
YMarks a special safety message.
.Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consultsymbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
YThe symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
YOnly qualified persons should test, maintain, and repair this
unit.
YDuring servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
DDo not touch live electrical parts.
DStop engine before testing or repairing unit un-
less the procedure specifically requires an en-
ergized unit.
DInsulateyourself from ground by standing or working on dry insu-
latingmats big enough to prevent contact with the ground.
DDo not leave live unit unattended.
DWhentesting live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
DStop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
MOVING PARTS can cause injury.
DKeep away from moving parts such as
fans, belts, and rotors.
DHave only qualified people remove
guards or covers for maintenance and
troubleshootingas necessary.
DKeephands, hair, loose clothing, and tools away from mov-
ing parts.
DBeforeworking on generator, remove spark plugs or injec-
tors to keep engine from kicking back or starting.
DBlock flywheel so that it will not turn while working on gener-
ator components.
DReinstallpanels or guards and close doors when servicing
is finished and before starting engine.
FLYING METAL can injure eyes.
DWear safety glasses with side shields or face
shield during servicing.
DBe careful not to short metal tools, parts, or
wires together during testing and servicing.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
ENGINE EXHAUST GASES can kill.
DDo not breathe exhaust fumes.
DUse in open, well-ventilated areas, or vent ex-
haustoutside and away from any building air in-
takes.
FUEL can cause fire or explosion.
DStopengine and let it cool off before checking or
addingfuel.
DDo not add fuel while smoking or if unit is near
any sparks or open flames.
DDo not overfill tank; clean up any spilled fuel.
BATTERY EXPLOSION can BLIND.
DAlways wear a face shield, rubber gloves, and
protective clothing when working on a battery.
DStop engine before disconnecting or connect-
ing battery cables.
DDo not allow tools to cause sparks when working on a battery.
DDo not use welder to charge batteries or jump start vehicles.
DObserve correct polarity (+ and –) on batteries.
DDisconnect negative (–) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
DDo not tip battery.
DReplace damaged battery.
DFlush eyes and skin immediately with water.

TM-4412 Page 2 D502K 5+4
STEAM AND HOT COOLANT can burn.
DIf possible, check coolant level when engine is
cold to avoid scalding.
DAlways check coolant level at overflow tank, if
present on unit, instead of radiator.
DIf the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
DWear safety glasses and gloves and put a rag over radiator cap.
DTurn cap slightly and let pressure escape slowly before completely
removingcap.
MAGNETIC FIELDS can affect pacemakers.
DPacemakerwearers keep away from servicing
areas until consulting your doctor.
FALLING UNIT can cause injury.
DUse equipment of adequate capacity to lift and
supportunit and components.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DSecurely attach components to lifting equip-
ment.
DIf using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
DAllow cooling period before servicing.
DWear protective gloves and clothing when
workingon a hot engine.
DDo not touch hot engine parts bare-handed.
SHOCK HAZARD from testing.
DStop engine before making or changing meter
lead connections.
DUse at least one meter lead that has a self-
retainingspring clip such as an alligator clip.
DRead instructions for test equipment.
TILTING OR TIPPING can cause injury.
DDo not put any body part under unit while lifting.
DAlways use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
DBe careful when working on stator and rotor assemblies.
H.F. RADIATION can cause interference.
DHigh-frequency(H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with elec-
tronic equipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the equip-
ment at once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
OVERUSE can cause OVERHEATING.
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
READ INSTRUCTIONS.
DUse Testing Booklet (Part No. 150 853) when
servicing this unit.
DConsultthe Owner’s Manual for welding safety
precautions.
DUse only genuine replacement parts.
DReinstall injectors and bleed air from fuel system according to
enginemanual.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Weldingcurrent, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
weldingor cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemakerwearers consult your doctor first. If cleared by your doctor,
thenfollowing the above procedures is recommended.

TM-4412 Page 3
D502K 5+4
SECTION 2 –DEFINITIONS
2-1. Symbols And Definitions
Stop Engine Fast (Run, Weld/
Power) Slow (Idle) Start Engine
Starting Aid Battery (Engine) Engine Oil
Pressure Engine Oil
Check Injectors/
Pump Check Valve Clearance Fuel Protective Earth (Ground)
Positive Negative Certified/Trained
Mechanic Welding Arc
AAmperes VVolts Panel/Local Remote
Engine Air Temperature Or
Engine
Temperature Output Alternating
Current
Stick (SMAW)
Welding Constant Current (CC) MIG (GMAW) Welding TIG (GTAW)
Time hHours sSeconds 1Single Phase
3Three Phase Read Operator’s
Manual Circuit Breaker Do Not Switch While Welding
Electrode
Connection Work Connection G
Engine-Driven,
Three-Phase
Alternator With
Rectifier Hz Hertz
Contactor On

TM-4412 Page 4 D502K 5+4
SECTION 3 –SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld
Output
Range
Rated Welding
Output
Maximum
Open-Circuit
Voltage Auxiliary Power Rating Engine Fuel
Capacity
CC/DC 20 –600 A 500 A, 40 Volts DC,
100% Duty Cycle 95 Standard:
Single-Phase, Kubota V3300-B Water-Cooled, Four 25 gal
CV/DC 14 –40 V
100% Duty Cycle
600 A, 44 Volts DC,
40% Duty Cycle 56
Single-Phase,
4 kVA/kW, 20/17 A,
120/240 V AC, 50/60 Hz
Water-Cooled, Four
Cylinder, 49 HP Diesel
Engine
25 gal
(95 L)
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height 50 in (1270 mm)
(to top of muffler) G
Width
28-1/2in (724 mm)
(mtg. brackets turned in)
30-3/4 in (781 mm)
(mtg. brackets turned out)
YDo not exceed tilt angles or engine could
be damaged or unit could tip.
YDo not move or operate unit where it could
tip.
Depth 69-1/2in (1765 mm) tip.
A69-1/2in (1765 mm)
B* 55-7/8in (1419 mm) A
C* 46-3/8in (1178) BC
D* 9-1/2in (241 mm)
E27-1/2in (699 mm)
°
F1 in (25 mm) H30°
°
G29-1/2in (749 mm) 20°30°
H9/16in (14 mm) Dia.
4 Holes Front Panel End
D20
20°
* With mounting brackets in center
position. Dimensions vary with loca-
tion of mounting brackets.
F
E
Weight 802 161-A
No fuel: 1808 lb (820 kg) 802 161-A 803 122

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

TM-4412 Page 6 D502K 5+4
3-4. Fuel Consumption
The curve shows typical fuel use
underweld or power loads.
208 137
US GAL./HR.
1.98
0.95
2.84
3.78
5.67
4.73
6.62
7.57
LITERS/HR.
0.00
8.51
9.46
10.40
11.35
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
0 100 200 300 400 500 600 700
DC WELD AMPERES AT 100% DUTY CYCLE
ContinuousWelding
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
withoutoverheating.
YExceeding duty cycle can
damage unit and void
warranty.
100% Duty Cycle At 500 Amperes
202 356

TM-4412 Page 7
D502K 5+4
3-6. AC Auxiliary Power Curve
193 018
The ac power curve shows the aux-
iliary power in amperes available at
the 120 and 240 volt receptacles.
0
50
100
150
200
250
300
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
AC VOLTS
0
25
50
75
100
150
125
0102030405060
AC AMPERES IN 120V MODE
3-7. Manufacturer’s Rating Label

TM-4412 Page 8 D502K 5+4
SECTION 4 –INSTALLATION
4-1. Installing Welding Generator (See Section 4-3)
install2 1/01–Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
1
2
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
GND/PE
34
YAlways securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other appli-
cable codes.
YAlways ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricityhazards.
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding Terminal
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
YIf unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
2
OR
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm) 18 in
(460 mm)
18 in
(460 mm)
OR
Movement Airflow Clearance Location
Grounding
OR
4-2. Installing Exhaust Pipe
1/2 in
Tools Needed:
803 122 / Ref. 802 169 / Ref. 202 705
YStop engine and let cool.
.Point exhaust pipe in desired di-
rection but always away from
frontpanel and direction of travel.

TM-4412 Page 9
D502K 5+4
4-3. Mounting Welding Generator
803 122 / Ref. 802 169-B
YDo not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
bracketsor bolt unit down.
1 Mounting Bracket
2 1/2 in Bolt And Washer
(Minimum –Not Supplied)
3 3/8-16 x 1 in Screws
(Supplied)
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mountunit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Tools Needed:
9/16 in
1
12
3
Welding Unit In Place
Bolting Unit In Place
4-4. Connecting The Battery
1/2 in
–
+
YConnect Negative (–) Cable Last.
Tools Needed:
802 168-E / Ref. 202 705 / 802 313 / S-0756-C
.Reinstallcover after connecting battery.

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

TM-4412 Page 11
D502K 5+4
1
4-6. Adding Coolant To Radiator
803 123-A / 206 580
YStop engine and let cool.
.Check coolant level according
to Section 4-5 before starting
this procedure.
Enginecoolant 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
radiatorfiller neck, add coolant as
follows:
1 RadiatorAir Bleed Screw
2 Radiator Cap
Removeair 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.
Reinstallair bleed screw and radia-
tor cap. Check coolant level in re-
covery tank (see Section 4-5).
Full
Capacity: w/Overflow
Tank 10 qt (9.5 L)
Tools Needed:
3/8 in
2

TM-4412 Page 12 D502K 5+4
4-7. Connecting To Weld Output Terminals
803 122
Tools Needed:
3/4 in
YStop engine.
1 Positive (+) Weld Output Terminal
2 Negative (–) Weld Output Terminal
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect elec-
trodeholder cable to Positive (+) terminal on
left and work cable to Negative (–) terminal
on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connectelectrode holder cable to Electrode
terminalon left and work cable to Work ter-
minal on right.
For MIG and FCAW welding Direct Current
ElectrodePositive (DCEP) on CC/CV mod-
els, connect wire feeder cable to Positive
(+) terminal on left and work cable to Nega-
tive (–) terminal on right. Use Process/Con-
tactor Control switch to select type of weld
output (see Section 5-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect wire feeder cable to Electrode ter-
minal on left and work cable to Work termi-
nal on right.
2
1

TM-4412 Page 13
D502K 5+4
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less 150 ft
(45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m)
Weld Output
Terminals
YStop engine before
connectingto weld out-
put terminals.
YDo not use worn, dam-
aged, undersized, or
poorly spliced cables.
Welding
Amperes
10 –60%
Duty
Cycle
60 –100%
Duty
Cycle 10 –100% Duty Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 3/0 (3x95)
600 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120)
700 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120) 4 ea. 4/0 (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2for metric use S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative.

TM-4412 Page 14 D502K 5+4
4-9. Connecting To Remote 14 Receptacle RC14
Socket* Socket Information
24 VOLTS AC
A24 volts ac. Protected by circuit
breaker CB5.
24 VOLTS AC
BContact closure to A completes
24 volt ac contactor control
circuit.
COutputto remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
REMOTE
OUTPUT
DRemotecontrol circuit common.
OUTPUT
CONTROL EDC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
OR 115 VOLTS AC I115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB13.
JContact closure to I completes
115 volt ac contactor control
circuit.
803 122 GND K Chassis common.
NEUTRAL GCircuit common for 24 and 115
volt ac circuit.
*The remaining sockets are not used.

TM-4412 Page 15
D502K 5+4
Notes

TM-4412 Page 16 D502K 5+4
SECTION 5 –OPERATING WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
206 212-A / 803 122
710
2
1
81213956
4
3
11