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IM694
RED-D-ARC
February, 2001
D503K 5+3 HO
10748
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment
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Summary of Contents for Red-D-Arc D503K 5+3 HO
- Page 1 For use with machines having Code Numbers: OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind.
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Page 2: California Proposition 65 Warnings
SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. -
Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
- Page 6 for selecting a QUALITY product. We want you to take pride in Thank You operating this product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
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Page 7: Table Of Contents
Cooling System .....................D-2 Battery ........................D-2 Hardware .......................D-3 Nameplates ......................D-3 Purging Air from Fuel System................D-3 Engine Service Chart ....................D-4 Troubleshooting ....................Section E Troubleshooting Guide ..................E-1 Machine Troubleshooting ..................E-2 Welder Troubleshooting ..................E-3 Diagrams ......................Section F Wiring Diagram .....................F-1 Parts Lists ........................P378 D503K 5+3 HO... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - Red-D-Arc D503K 5+3 HO INPUT - ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Kubota 4 cylinder High Idle 1800 202.5 cu. in 12VDC battery Fuel: 15 gal. V3300-EBG-RDA-1-S1 49.5 HP @ Full Load 1740... -
Page 9: Safety Precautions
Also, locate the welder so that the engine exhaust fumes are prop- erly vented to an outside area. D503K 5+3 HO... -
Page 10: High Altitude Operation
Operator’s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine Operator’s Manual for the proper ser- vice and maintenance intervals. D503K 5+3 HO... -
Page 11: Spark Arrester
The U.S. dations. National Electrical Code lists a number of alternate ------------------------------------------------------------------------ means of grounding electrical equipment. A machine grounding stud marked with the symbol is provid- ed on the welding generator frame foot. D503K 5+3 HO... -
Page 12: Operation
GENERAL DESCRIPTION Air Cleaner - Heavy duty two stage dry type. The D503K 5+3 HO is a heavy duty, engine driven, Muffler - A muffler and exhaust outlet elbow are stan- DC arc welding power source, capable of providing dard. -
Page 13: Engine Operation
45 sec. DUTY CYCLE Note: Extreme cold weather starting may require The output rating of the D503K 5+3 HO is 400 longer glow plug operation as well as engine oil and amperes at 40 arc volts on a 100% duty cycle. -
Page 14: Current Controls
“Job Selector” back to the center of the black range. Then turn the “Current Control” up or down a little as needed. Readjust the “Job Selector” for the exact characteristics and current desired. D503K 5+3 HO... -
Page 15: Maintenance
MAINTENANCE ENGINE AIR FILTER SAFETY PRECAUTIONS The engine air filter element is a dry cartridge type. It WARNING is located above the engine. It can be cleaned and re- Have qualified personnel do the maintenance used; however, damaged elements should not be work. -
Page 16: Cooling System
MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM The D503K 5+3 HO is equipped with a pressure radia- WARNING tor. Keep the radiator cap tight to prevent loss of Uncovered rotating equipment can be dangerous. coolant. Clean and flush the cooling system periodi-... -
Page 17: Hardware
(use pre-heat if needed. DO NOT CRANK STARTER FOR MORE THAN 1 MINUTE OUT OF 5 MINUTES. 4. Close air bleed screw when fuel is observed returning to the fuel tank. (Remove fuel cap to observe). D503K 5+3 HO... -
Page 18: Engine Service Chart
The air cleaner cover can then be removed and the element taken out. Above operations to be carried out by trained personnel with reference to the workshop manual where necessary. These preventive maintenance periods apply to average conditions of operation. If necessary use shorter periods. D503K 5+3 HO... - Page 19 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
- Page 20 Engine running at varying speeds. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. D503K 5+3 HO...
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Page 21: Troubleshooting
Faulty connections to auxiliary receptacles. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. D503K 5+3 HO... -
Page 22: Diagrams
DIAGRAMS D503K 5+3 HO... - Page 23 NOTES D503K 5+3 HO...
- Page 24 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 25 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 26 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...
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