Red-D-Arc D502K 5+2 Specifications

OM-228 921G 2009−02ProcessesDescriptionAir Carbon Arc (CAC-A) Cuttingand GougingStick (SMAW) WeldingEngine Driven Welding GeneratorTIG (GTAW) WeldingM

OM-228 921 Page 6H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcomm

OM-228 921 Page 7SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2008−08freSe protéger, ainsi que toute autre personne travaillant sur l

OM-228 921 Page 8DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de r

OM-228 921 Page 9LES CHAMPS MAGNETIQUES peuventaffecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à

OM-228 921 Page 10L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonox

OM-228 921 Page 11LIRE LES INSTRUCTIONS. Lire le manuel d’utilisation avant d’installer,d’utiliser ou d’intervenir sur l’appareil. N’utiliser que le

OM-228 921 Page 12Le MÉTAL CHAUD provenant dudécoupage ou du gougeage à l’arc risquede provoquer un incendie ou une explosion. Ne pas découper ou gou

OM-228 921 Page 13LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer de

OM-228 921 Page 142-9. Information EMFConsidérations sur le soudage et les effets de basse fréquence et deschamps magnétiques et électriques.Le couran

OM-228 921 Page 15SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStarting Aid Battery (En

OM-228 921 Page 16SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRated WeldingOutputMaximumOpen-Circui

OM-228 921 Page 174-3. Volt-Ampere Curves208 135 / 203 415 / 208 136The volt-ampere curves show theminimum and maximum voltageand amperage output capa

OM-228 921 Page 184-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.208 137US GAL./HR.1.980.952.843.785.674.736.627.57LIT

OM-228 921 Page 194-6. Generator Power Curve193 018The AC power curve shows thegenerator power in amperes avail-able at the 120 and 240 voltreceptacle

OM-228 921 Page 204-7. Optional Three-Phase Generator Curves197 472 / 197 473The AC power curves show thegenerator power available in am-peres at the

OM-228 921 Page 21SECTION 5 − INSTALLATION! Do not move or operate unitwhere it could tip.! Always securely fasten weld-ing generator onto transportve

OM-228 921 Page 225-2. Mounting Welding GeneratorTools Needed:9/16 in.224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on

OM-228 921 Page 23! Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.! Also see AWS Safety &

OM-228 921 Page 245-5. Using Lifting EyeLift1 2008−01 804 7121 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting

OM-228 921 Page 255-7. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol U

OM-228 921 Page 265-9. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break

OM-228 921 Page 2715-10. Adding Coolant To Radiator804 583-A / 228 923! Stop engine and let cool. Check coolant level accordingto Section 5-9 before

OM-228 921 Page 285-11. Connecting To Weld Output Terminals804 582 / 228 923 / 803 778-BTools Needed:83/4 in.7MIG and FCAW WeldingFor MIG and FCAW wel

OM-228 921 Page 295-12. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or L

OM-228 921 Page 305-13. Connecting To Remote 14 Receptacle RC14OR804 582-ASocket* Socket Information24 VOLTS ACA 24 volts AC. Protected bysupplementar

OM-228 921 Page 31Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/1

OM-228 921 Page 32SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)236 982-A / 804 582-A710218129564311

OM-228 921 Page 336-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Start/Preheat SwitchUse switch to start engine a

OM-228 921 Page 346-3. Process/Contactor Control Switch1 Process/Contactor Control Switch(See Section 6-1 For Location)! Weld output terminals are ene

OM-228 921 Page 356-4. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Section 5-13).0774 / Ref.

TABLE OF CONTENTSSECTION 8 − MAINTENANCE & TROUBLESHOOTING 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-228 921 Page 366-5. Fuel/Hour Gauge Descriptions

OM-228 921 Page 37SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Receptacles21191 62434 Generator power is not af-fected by weld

OM-228 921 Page 387-2. Connecting To Optional Three-Phase Generator (High KVA Models Only)Ref. 197 399 / 802 332-B / 803 655 Place Process/Contactor

OM-228 921 Page 39SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Maintenance Label

OM-228 921 Page 408-2. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service,

OM-228 921 Page 418-3. Servicing Air Cleaneraircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B! Stop engine.NOTICE − Do not run engine witho

OM-228 921 Page 428-4. Inspecting/Cleaning Optional Spark Arrestor Ref. 228 923-A / 804 582-A! Stop engine and let cool.1 Spark Arrestor Muffler2 Clea

OM-228 921 Page 438-6. Adjusting Engine Speed804 583-A / Ref. 228 932-A! Stop engine and let cool.Engine speed is factory set andshould not require ad

OM-228 921 Page 448-7. Servicing Fuel And Lubrication Systems Ref. 800 159-E / Ref. 802 170 / 804 583-B! Stop engine and let cool.! After servicing, s

OM-228 921 Page 458-8. Servicing Engine Cooling SystemRef. 804 583-A / Ref. 803 136! Stop engine and let cool.1 Radiator Cap2 RAdiator Air Bleed Screw

OM-228 921 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2008−08Protect yourself and others from injury — read and follow these precauti

OM-228 921 Page 468-9. Overload Protection! Stop engine.1 Fuse F12 Fuse F2F1 and F2 protect the stator exciterwinding from overload. If F1 opens,weld

OM-228 921 Page 478-10. Troubleshooting TablesA. WeldingTrouble RemedyNo weld output; generator power outputokay at AC receptacles.Place Process/Conta

OM-228 921 Page 48Trouble RemedyRepair or replace wire feeder.Low CV weld output. Set Amperage Range switch S3 to highest range.Min or max CV weld out

OM-228 921 Page 49Trouble RemedyCheck engine wiring harness plug connections.Have Factory Authorized Service Agent check continuity of Engine Start/P

OM-228 921 Page 50SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For Welding Generator

OM-228 921 Page 51237 497-C

OM-228 921 Page 52SECTION 10 − RUN-IN PROCEDURErun_in1 2007−0410-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current d

OM-228 921 Page 5310-2. Run-In Procedure Using Load BankS-0683! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep exha

OM-228 921 Page 5410-3. Run-In Procedure Using Resistance GridS-0684! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Kee

OM-228 921 Page 55SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding ge

OM-228 921 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. K

OM-228 921 Page 5611-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-228 921 Page 5711-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-228 921 Page 5811-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-228 921 Page 5911-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8

OM-228 921 Page 6011-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalS

OM-228 921 Page 6111-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, u

OM-228 921 Page 62SECTION 12 − PARTS LIST Hardware is common andnot available unless listed.13546911131415161718198384868788919293959697989910091101

OM-228 921 Page 63804 572-D202122232425262731303233343538363740433044564647495051525369686766656463575859608079787776733028298139424145485455707172 (F

OM-228 921 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 +199294 Panel, Gen Lh Stainless 1. . . . . . . . . . . . . .

OM-228 921 Page 65DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity51 189975 Hinge, Door Access 180 Deg. 2. . . . . .

OM-228 921 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a b

OM-228 921 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity99 228924 Label, Manufacturing Rating D502K 5+20 Ku

OM-228 921 Page 67803 203-D1234567891011121314151617Figure 12-2. Control Box AssemblyDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Control Box Assemb

OM-228 921 Page 68 Hardware is common andnot available unless listed.804 700-B3129283027222123242526203234333512131918171615145681112 (Fig 12−4)79104

OM-228 921 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Panel, Front w/Components (Continued)Quantity6 S5 011609 Switch, Tgl Spdt 15a 125vac

OM-228 921 Page 70 Hardware is common andnot available unless listed.1911614171520611712139108432518Figure 12-4. Auxiliary Power Panel, High KVADescr

OM-228 921 Page 71 Hardware is common andnot available unless listed.803 204-B56892530313233347272829373635124326101122121920181714161513212324Figure

OM-228 921 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-5. Generator (Continued)Quantity24 191579 Cover, Starter Hole 2. . . . . . . . . . . .

OM-228 921 Page 73 Hardware is common andnot available unless listed.802 279-A123465789Figure 12-6. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs

OM-228 921 Page 74Notes

Effective January 1, 2009(Equipment with a serial number preface of LK or newer)This limited warranty supersedes all previous manufacturerswarranties

OM-228 921 Page 4HYDRAULIC FLUID can injure or kill. Before working on hydraulic system, turn off andlockout/tagout unit, release pressure, and be su

ORIGINAL INSTRUCTIONS − PRINTED IN USA 2009−01Model Name Serial/Style NumberPurchase Date (Date which equipment was delivered to original customer.)Di

OM-228 921 Page 5MOVING PARTS can injure. Keep away from fans, belts and rotors. Keep all doors, panels, covers, and guardsclosed and securely in pl