Red-D-Arc Welderentals D502DX 5+4 Owner'S Manual Download Page 1

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Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

OM-224 690H

2009

−

Flux Cored (FCAW) Welding

File: Engine Drive

Summary of Contents for D502DX 5+4

Page 1: ...Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding OM 224 690H 2009 01 Flux Cored FCAW Welding File Engine Drive...

Page 2: ......

Page 3: ...ess Labels 15 3 2 Symbols And Definitions 16 SECTION 4 SPECIFICATIONS 17 4 1 Weld Power And Engine Specifications 17 4 2 Dimensions Weights And Operating Angles 17 4 3 Volt Ampere Curves 18 4 4 Fuel C...

Page 4: ...5 Checking Generator Brushes 36 8 6 Adjusting Engine Speed 37 8 7 Servicing Fuel And Lubrication Systems 38 8 8 Overload Protection 39 8 9 Troubleshooting 40 SECTION 9 ELECTRICAL DIAGRAMS 44 SECTION 1...

Page 5: ...gh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC m...

Page 6: ...ding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire...

Page 7: ...engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual If the engine is warm...

Page 8: ...1 5 Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons sho...

Page 9: ...LLING UNIT can cause injury Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications Lift and support unit...

Page 10: ...parky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code f...

Page 11: ...l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structur...

Page 12: ...ter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tinc...

Page 13: ...ieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une sou...

Page 14: ...blessures ou m me la mort Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique...

Page 15: ...utiliser l appareil contr ler les composants du circuit d air comprim les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure Ne pas diriger un jet d air vers...

Page 16: ...rop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il y a lieu LES TINCELLES VOLANTES ris quent de provoquer des blessures Porter un cran facial pour prot ger le visage et le...

Page 17: ...ou autres probl mes de procr ation Se laver les mains apr s manipu lation Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconna...

Page 18: ...endant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les...

Page 19: ...rds as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load above 200 ampe...

Page 20: ...Local Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phas...

Page 21: ...d Operating Angles Dimensions 802 161 A Front Panel End D B A F E H G C Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip 20 20 30 3...

Page 22: ...other settings fall between the curves shown DC AMPERES DC VOLTS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges 230 Max 170 365 110 225 70 130 55 85 4 4 Fuel Consumption The curve...

Page 23: ...ding duty cycle can damage unit and void warranty 100 Duty Cycle At 400 Amperes 215 084 A 4 6 AC Generator Power Curve 193 018 The ac power curve shows the gen erator power in amperes available at the...

Page 24: ...nd other applica ble codes NOTICE Do not install unit where air flow is restricted or engine may overheat See Section 4 2 for lifting eye rating See Section 5 2 for mounting in formation install3 2008...

Page 25: ...s Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1...

Page 26: ...GFCI re ceptacles use GFCI pro tected extension cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to...

Page 27: ...the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied Tools Needed 2 1 3 5 6 Installing Exhaust Pipe 1...

Page 28: ...electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger 5 5 Amperes For 30 Minutes Charge Time 6 30 Amperes For 12...

Page 29: ...ring run in see Section 10 Fuel NOTICE Do not use gasoline Gasoline will damage engine The unit is shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before start...

Page 30: ...ld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place any thing between weld cable terminal and copper bar Make sure that...

Page 31: ...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 2x9...

Page 32: ...OM 224 690 Page 28 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 236 984 A Ref 804 168 9 1 6 10 7 5 4 3 2 8...

Page 33: ...tage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 7 5 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amp...

Page 34: ...age Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 236 984 A Ref 804 168 In Example Range 110 to 225 A DC Percentage Of Range 50 Max About 168 A DC 50 of 110 to 22...

Page 35: ...OM 224 690 Page 31 6 5 Fuel Hour Gauge Descriptions...

Page 36: ...on to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work Place...

Page 37: ...8 7 qt D912L03 8 5 L 9 qt D2011L04i 8 5 L 9 qt API CD CE CF 4 D2011L03 4i MILLER 067 265 Deutz 117 4416 Fram PH46 D912L03 MILLER 064 677 1 5L Opt 066 212 1L Deutz 117 4418 1 5L Opt 117 4417 1L Fram PH...

Page 38: ...WATER Section 5 9 8 7 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 100 Hours Section 8 3 Battery Terminals Air Cleaner Hoses Air Cleaner Element Weld Terminals Every 250 Hours 1 2 i...

Page 39: ...ent three times 1 Intake Manifold 2 Service Indicator Optional 3 Window 4 Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to...

Page 40: ...nout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 8 5 Checking Generator Brushes...

Page 41: ...ter or fre quency meter see table for no load speeds If necessary adjust speed as follows Start engine and run until warm Place Stick TIG switch in Stick position Standard Models 1 Engine Speed Adjust...

Page 42: ...fuel flows To replace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and turn clock wise Bleed air...

Page 43: ...ay stick to the workpiece more frequently during low voltage short arc length conditions CB4 automatically resets when the fault is corrected CB10 protects the engine battery circuit If CB10 opens the...

Page 44: ...ns inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check br...

Page 45: ...lug connections Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1 Engine cranks but does not start Check fuel level Check battery and replace if necessary Chec...

Page 46: ...t check idle module PC7 and current transformer CT1 Check for obstructed throttle solenoid Engine does not run at idle speed models with idle option only Place Stick TIG Selection switch in Stick posi...

Page 47: ...362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in...

Page 48: ...OM 224 690 Page 44 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For CC Welding Generator...

Page 49: ...OM 224 690 Page 45 237 428 A...

Page 50: ...ngs seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during...

Page 51: ...nerator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A...

Page 52: ...tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then a...

Page 53: ...ock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cab...

Page 54: ...ve load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when...

Page 55: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100...

Page 56: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1...

Page 57: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Vol...

Page 58: ...k to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Insta...

Page 59: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GF...

Page 60: ...12 PARTS LIST Hardware is common and not available unless listed 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 89 90 91 92 93 94 95 96 97 98 99 100 101 102 Fig 12 5 103 104 105 106 Fig 12 3 107 Fig 12 2...

Page 61: ...C 19 20 21 22 23 24 25 26 27 28 Fig 12 4 30 31 32 33 34 35 36 29 38 39 41 40 42 43 44 45 46 29 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 81 80 82...

Page 62: ...22 192 041 LABEL use diesel fuel only 1 23 222 513 LABEL warning falling equipment can cause serious 1 24 224 265 LABEL warning hot exhaust parts do not touch 1 25 105 734 PIPE muffler extension elbo...

Page 63: ...iffener engine access 1 65 199 592 LATCH paddle series 20 black 1 66 237 352 LABEL maintenance big blue deutz series ce 1 67 200 989 DOOR engine access 1 68 189 975 HINGE door access 180deg 2 69 208 1...

Page 64: ...IFIER ASSEMBLY 1 103 191 448 TOP cover front upright 1 104 201 750 UPRIGHT front 1 105 233 953 LABEL warning general precautionary CSA 1 106 Figure 12 3 PANEL front w components 1 107 212 944 LABEL cc...

Page 65: ...TROL BOX rh 1 8 CR1 214 876 RELAY encl 6vds spst 35a 14vdc 5 pin 1 9 D8 C8 D12 189 701 DIODE CAPACITOR BOARD 1 10 CB10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 11 CR5 223 710 RELAY encl 12vdc dp...

Page 66: ...nn Rect Univ 039 6p S 3row Plug Cable Lkg 5 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 092670 Conn Rect Univ 084 3p...

Page 67: ...2 6 3 5 4 23 11 22 31 27 Figure 12 3 Panel Front w Components Description Part No Dia Mkgs Item No Figure 12 3 Panel Front w Components Figure 12 1 Item 106 Quantity 1 019 602 KNOB pointer 1 2 236 98...

Page 68: ...NEL mtg terminal pwr output 1 18 039 046 TERMINAL pwr output black 1 180 735 WASHER output stud 2 19 181 169 SPACER output stud 2 20 186 621 BOOT generic output stud 2 21 039 047 TERMINAL pwr output r...

Page 69: ...GUARD generator wire mesh 1 9 172 674 SPRING ext 240 OD x 041 wire x 3 500pld 2 10 039 207 BAFFLE air 1 11 ROTOR 212 996 ROTOR Generator Segmented Assy Includes 1 12 210 824 ROTOR Generator Includes...

Page 70: ...190 823 BRUSH contact 3 32 208 469 CLIP spring 3 33 189 142 BRUSHHOLDER ASSEMBLY gen 1 34 602 242 WASHER flat 375IDx0 875odx 083t stl pld 2 35 602 211 WASHER Lock 318idx0 586odx 078t Stl Pld Split 31...

Page 71: ...er AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 215 755 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HE...

Page 72: ...OM 224 690 Page 68 Notes...

Page 73: ...OM 224 690 Page 69 Notes...

Page 74: ...OM 224 690 Page 70 Notes...

Page 75: ...ot apply to 1 Consumable components such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2 Items furnished by manufacturer but manufactured b...

Page 76: ...iginal customer Distributor Address City State Zip Please complete and retain with your personal records Contact the Delivering Carrier for For assistance in filing or settling claims contact your dis...

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