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Red-D-Arc D502K 5+2 Owner's Manual

Cc/cv dc diesel welder
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OM-4412
206 995B
November 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

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Summary of Contents for Red-D-Arc D502K 5+2

  • Page 1 OM-4412 206 995B November 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...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. Symbol Usage .
  • Page 4 TABLE OF CONTENTS SECTION 7 – MAINTENANCE & TROUBLESHOOTING ........7-1.

  • Page 5: Symbol Usage

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING rom _nd_10/02 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    BUILDUP OF GAS can injure or kill. FLYING METAL can injure eyes. D Shut off shielding gas supply when not in use. D Welding, chipping, wire brushing, and grinding D Always ventilate confined spaces or use cause sparks and flying metal. As welds cool, they can throw off slag.

  • Page 7: Compressed Air Hazards

    MOVING PARTS can cause injury. ENGINE EXHAUST GASES can kill. D Keep away from fans, belts, and rotors. D Use equipment outside in open, well-ventilated D Keep all doors, panels, covers, and guards areas. D If used in a closed area, vent engine exhaust closed and securely in place.

  • Page 8: Principal Safety Standards

    FLYING SPARKS can cause injury. H.F. RADIATION can cause interference. D Wear a face shield to protect eyes and face. D High-frequency (H.F.) can interfere with radio D Shape tungsten electrode only on grinder with navigation, safety services, computers, and communications equipment.

  • Page 9: Signification Des Symboles

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 4/02 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer D Porter des gants et des vêtements de protection pour leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement

    DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.

  • Page 12: Principales Normes De Sécurit

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Symbols And Definitions

    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 Amperes...

  • Page 14: Section 3 – Specifications

    SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Weld Maximum Welding Rated Welding Generator Power Fuel Output Open-Circuit Engine Mode Output Rating Capacity Range Voltage 500 A, 40 Volts DC, CC/DC Standard: Kubota V3300-B 20 – 600 A 100% Duty Cycle 100% Duty Cycle Single-Phase,...

  • Page 15: Volt-Ampere Curves

    3-3. Volt-Ampere Curves The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the Ranges curves shown. 300 – Max 185 – 525 125 –...

  • Page 16: Fuel Consumption

    3-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 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 DC WELD AMPERES AT 100% DUTY CYCLE 208 137 3-5.

  • Page 17: Generator Power Curve

    3-6. Generator Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 193 018 3-7. Manufacturer’s Rating Label OM-4412 Page 13...

  • Page 18: Installing Welding Generator

    SECTION 4 – INSTALLATION -1. Installing Welding Generator Y Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- Movement ble codes. Y Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

  • Page 19: Mounting Welding Generator

    4-2. 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 brackets or bolt unit down. Supporting The Unit Y Do not mount unit by sup- porting the base only at the four mounting brackets.

  • Page 20: Installing Exhaust Pipe

    4-3. 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 4-4.

  • Page 21: Engine Prestart Checks

    4-5. Engine Prestart Checks Check radiator coolant Remove air bleed screw level when fluid is low in when filling radiator. recovery tank. See Section 4-6. Full Full Capacity: w/Overflow Tank 10 qt (9.5 L) Diesel Full Coolant Recovery Tank Full 803 123-A tions).

  • Page 22: Adding Coolant To Radiator

    4-6. Adding Coolant To Radiator Y Stop engine and let cool. Check coolant level according to Section 4-5 before starting this procedure. Engine coolant is a mixture of water and ethylene glycol base anti- freeze. A solution of 50% antifreeze and 50% water must be used in this engine.

  • Page 23: Connecting To Weld Output Terminals

    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 Positive (+) Weld Output Terminal If equipped with optional polarity switch, output (see Section 5-3).

  • Page 24: Selecting Weld Cable Sizes

    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)

  • Page 25: Connecting To Remote 14 Receptacle Rc

    4-9. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 volts ac. Protected by circuit breaker CB5. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit. Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG mode.

  • Page 26: Section 5 – Operating Welding Generator

    SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) 206 212-A / 803 122 OM-4412 Page 22...

  • Page 27: Description Of Front Panel Controls (See Section)

    5-2. Description Of Front Panel Controls (See Section 5-1) Engine Starting Controls Fuel Gauge perage within range selected by Amperage Range switch. With Process/Contactor Con- Start/Preheat Switch Use gauge to check fuel level when engine is trol switch in any MIG position, use control to running.

  • Page 28: Process/Contactor Control Switch

    5-3. Process/Contactor Control Switch 206 212-A 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...

  • Page 29: Remote Voltage/Amperage Control

    5-4. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 4-9). In Example: Example: Combination Remote Amperage Control (Stick) With Remote On/Off Control Process = Stick (Using Remote On/Off) Range = 125 to 400 A DC Min = 125 A DC Max = 400 A DC Max (400 A DC)

  • Page 30: Volt And 240 Volt Receptacles

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Receptacles Generator power is not af- fected by weld output. 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 31: Section 7 - Maintenance & Troubleshooting

    SECTION 7 – MAINTENANCE & TROUBLESHOOTING 7-1. Maintenance Label OM-4412 Page 27...

  • Page 32: Routine Maintenance

    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. See also Engine Manual and Maintenance Label. Recycle engine Service engine more often if used in severe condi- fluids.
  • Page 33 Every 500 h Clean Radiator Replace Fan Belt. Air Hose Exterior. Check And Repair Or Clean Spark Replace Arrestor. See Cracked Section 7-4. Cables. Every 800 h Replace Primary Replace Secondary Fuel Fuel Filter. See Filter. See Section 7-6. Section 7-6. Check Valve Clearance.* Every 1000 h...

  • Page 34: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- 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.

  • Page 35: Inspecting/Cleaning Optional Spark Arrestor

    7-4. Inspecting/Cleaning Optional Spark Arrestor Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe With Rain Cap 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.

  • Page 36: Adjusting Engine Speed

    7-5. Adjusting Engine Speed Y Stop engine and let cool. 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).

  • Page 37: Servicing Fuel And Lubrication Systems

    7-6. Servicing Fuel And Lubrication Systems Tools Needed: Right Side 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 Y Beware of fire.

  • Page 38: Servicing Engine Cooling System

    7-7. Servicing Engine Cooling System Y Stop engine and let cool. Radiator Cap RAdiator Air Bleed Screw Radiator Drain Cock 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.

  • Page 39: Overload Protection

    7-8. Overload Protection Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely.

  • Page 40: Troubleshooting

    7-9. Troubleshooting A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor Control switch in a Electrode Hot position, or place switch in a Remote position okay. and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-9 and 5-1). Check position of Amperage Range switch.
  • Page 41 Trouble Remedy Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust Control switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. B. Generator Power Trouble Remedy No generator power output;...
  • Page 42 Trouble Remedy Engine suddenly stops. Check fuel level. Check engine oil level. Engine stops if engine oil pressure is too low. Check engine coolant level. Engine Shutdowns if engine temperature is too high (see Section 4-5). See engine manual. Engine slowly stopped and cannot be Check fuel level.
  • Page 43 Notes OM-4412 Page 39...

  • Page 44: Section 8 - Electrical Diagram

    SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator OM-4412 Page 40...
  • Page 45 206 628-B OM-4412 Page 41...

  • Page 46: Section 9 - Run-In Procedure

    SECTION 9 – RUN-IN PROCEDURE run_in1 8/01 9-1. Wetstacking Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 47: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 48: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 49: Grounding Generator To Truck Or Trailer Frame

    SECTION 10 – GENERATOR POWER GUIDELINES 10-1. Selecting Equipment Generator Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Y Do not use 2-prong plug un- less equipment is double in- sulated.

  • Page 50: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 51 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 52 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 53 10-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 54 10-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Fused Utility Welding Disconnect Electrical Generator Transfer Switch Switch Service Output (If Required) Essential Loads Y Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-...
  • Page 55 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 56: Section 11 - Parts List

    SECTION 11 – PARTS LIST Hardware is common and not available unless listed. 109 (Fig. 11-5) 101 (FIG. 11-2) 107 (FIG. 11–3) Figure 11-1. Main Assembly OM-4412 Page 52...
  • Page 57 72 (Fig 11-4) 803 201-B OM-4412 Page 53...
  • Page 58 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ....+199294 Panel, Gen Lh Stainless ......... .
  • Page 59 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly (Continued) ....189975 Hinge, Door Access 180 Deg........
  • Page 60 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly (Continued) ..189699 Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt ......
  • Page 61 Item Dia. Part Mkgs. Description Quantity Figure 11-2. Control Box Assembly (Figure 11-1 Item 101) ..F1, F2 . . . 085874 Fuse, Mintr Cer Slo–blo 10. Amp 250 Volt ......
  • Page 62 Hardware is common and not available unless listed. 803 202 Figure 11-3. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-3. Panel, Front w/Components (Figure 11-1 Item 107) ....206212 Plate, Screened Ident Control .
  • Page 63 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Panel, Front w/Components (Continued) ....206809 Harness, Weld Control (consisting of) .......
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Panel, Front w/Components (Continued) ....193158 Harness, Unit Weld Control – CV (consisting of) .
  • Page 65 Item Dia. Part Mkgs. Description Quantity Figure 11-4. Generator (Figure 11-1 Item 72) ....132053 Screw, 375-16 X 1.50hexhd Pln Gr 5pld ......
  • Page 66 Hardware is common and not available unless listed. 802 279-A Figure 11-5. Main Rectifier Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-5. Main Rectifier Assembly (Figure 11-1 Item 109) ...

  • Page 67: Warranty

    Warranty Effective January 1, 2001 (Equipment with a serial number preface of “LB” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or warranties expressed or implied. Consumable components;...
  • Page 68 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 Contact the Delivering Carrier to: File a claim for loss or damage during shipment.

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