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Red-D-Arc D502K 5+4, Technical Manual

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Red-D-Arc D502K 5+4 Technical Manual Download Page 7

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

A

Amperes

V

Volts

Panel/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 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

Summary of Contents for D502K 5+4

Page 1: ...rch 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 FCA...

Page 2: ...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 PAR...

Page 3: ...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 P...

Page 4: ......

Page 5: ...and rotors D Have only qualified people remove guards or covers for maintenance and troubleshootingas necessary D Keep hands hair loose clothing and tools away from mov ing parts D Before working on...

Page 6: ...ualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equip ment at once D Have the installation r...

Page 7: ...ositive Negative Certified Trained Mechanic Welding Arc A Amperes V Volts Panel Local Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current...

Page 8: ...gal 95 L 3 2 Dimensions Weights And Operating Angles Dimensions Height 50 in 1270 mm to top of muffler G Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out Y Do no...

Page 9: ...ll 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...

Page 10: ...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 Continuous Welding 3 5 Duty Cycle And Overheating Duty...

Page 11: ...ower 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 0 10...

Page 12: ...ame to vehicle frame to pre vent electric shock and static electricity hazards 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated co...

Page 13: ...lace 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 o...

Page 14: ...run in Check oil several times daily during run in Coolant Check coolant level in radiator before start ing unit the first time Add coolant if below bottom of filler neck see Section 4 6 for ra diator...

Page 15: ...be used in this engine Do not use 100 antifreeze or severe damage will occur If coolant level is below bottom of radiator filler neck add coolant as follows 1 Radiator Air Bleed Screw 2 Radiator Cap...

Page 16: ...ipped with optional polarity switch connect electrode holder cable to Electrode terminal on left and work cable to Work ter minal on right For MIG and FCAW welding Direct Current Electrode Positive DC...

Page 17: ...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...

Page 18: ...ck mode 0 to 10 volts dc in TIG mode REMOTE OUTPUT D Remote control circuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust...

Page 19: ...TM 4412 Page 15 D502K 5 4 Notes...

Page 20: ...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 7 10 2 1 8 12 13 9 5 6 4 3 11...

Page 21: ...ee Section 5 3 for Process Contactor Con trol switch information 8 Amperage Range Switch Y Do not switch under load Use switch to select weld amperage range Use the lowest four ranges for Stick and TI...

Page 22: ...is in a Weld Terminals Always On CC Stick position the arc drive dig circuit provides additional amperage during low voltage short arc length conditions to prevent sticking electrodes The arc drive di...

Page 23: ...400 A DC Min 125 A DC Max 400 A DC Adjust Optional Remote Control Set V A Adjust Switch Set Range Control Not Used In Remote Stick Mode Max 400 A DC Min 125 A DC Set Remote Process Example Combination...

Page 24: ...cle Press button to reset GFCI1 At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects...

Page 25: ...TM 4412 Page 21 D502K 5 4 SECTION 7 MAINTENANCE 7 1 Maintenance Label...

Page 26: ...be done by Factory Authorized Service Agent 8 h Wipe Up Spills Check Fluid Levels See Section 4 5 Coolant Full OIL Full 50 h Clean And Tighten Weld Terminals Check Fuel Lines And Connections 100 h Ch...

Page 27: ...place Primary Fuel Filter See Section 7 6 Check Valve Clearance 1000 h Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Drain Sludge From Fuel Tank See Section 7...

Page 28: ...nal engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning...

Page 29: ...Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe With Raincap Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole br...

Page 30: ...eeds If necessary adjust speed as follows Start engine and run until warm Turn Process Contactor Control switch to Stick Electrode Hot position 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut...

Page 31: ...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 from...

Page 32: ...em Ref 803 123 A 803 136 Y Stop engine and let cool 1 Radiator Cap 2 RAdiator Air Bleed Screw 3 Radiator Drain Cock Drain engine coolant according to procedure in engine manual Add engine coolant acco...

Page 33: ...lt output to field current regulator board PC1 If CB5 opens weld output and 24 volt output to RC14 stops If CB5 con tinues to open check remote controls connected to RC14 and circuit board PC6 see Sec...

Page 34: ...back to voltage amperage set ting of R1 9 LED Board PC9 Monitors power remote control command engine rpm and field ex citation inputs to PC1 10 Circuit Breakers CB5 CB13 Protects PC6 RC14 from overloa...

Page 35: ...of dc weld output 22 Voltmeter V1 Ammeter A1 Display weld voltage and current 23 Electrode And Work Weld Output Terminals Provide weld output Without optional Polarity AC Selector switch S13 termi nal...

Page 36: ...t breaker can be reset CB1 DIODE A device that allows current to flow in one direction only Most common use is to change AC to DC D1 FUSE A protection device usually an enclosed piece of wire that mel...

Page 37: ...tc Circuit diagrams schematics always show the contact points in the power off state CR1 CR1 COIL NRM OPEN POINTS NRM CLOSED POINTS THERMOSTAT NORMALLY OPEN AND NORMALLY CLOSED This is a switch that c...

Page 38: ...switch When a signal is applied to the gate G current is allowed to flow from the emitter E to the collector C This device is typically used in Invertor designed welding machines to control the weldin...

Page 39: ...H1 OR TRANSFORMER A device that changes AC voltage from one magnitude to another Typically used to reduce high primary voltages to lower welding voltages T1 INTEGRATED BRIDGE RECTIFIER An arrangement...

Page 40: ...sconnect leads 105 and 108 from rotor and check continuity across slip rings Replace rotor if neces sary No weld output or auxiliary power output Disconnect equipment from auxiliary power receptacles...

Page 41: ...om the rotor and check continuity across slip rings Replace rotor if nec essary Low open circuit voltage Check engine speed and adjust if necessary see Section 7 5 No remote fine amperage or voltage c...

Page 42: ...If R3 is replaced adjust R3 see Section 10 12 Low output at auxiliary power receptacles Check engine speed and adjust if necessary see Section 7 5 Check fuse F1 and replace if open see Section 7 8 Che...

Page 43: ...Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 7 1 Engine suddenly stops Check oil level Automatic shutdown system stops engine if oil pressure is...

Page 44: ...m For Welding Generator Use With Section 10 3 Adjust R3 according to Section 10 12 V7 V5 R5 V8 R7 V9 R8 V17 V18 V19 See Section 4 9 for RC14 information See Section 10 5 for PC6 data V20 V21 V6 R6 V4...

Page 45: ...B V10 V12 R11 See Section 8 for PC3 information R9 V11 R10 See Section 8 for PC4 PC5 information PC1 power supply relay CR5 206 628 A V23 V22 V24 Engine temp latching relay CR2 Engine oil pressure lat...

Page 46: ...3 89 volts dc S6 in Weld Terminals Always On Stick position 47 volts dc S6 in Weld Terminals Always On Scratch Start Tig position 16 to 56 volts dc from min to max of R1 S6 in Weld Terminals Always On...

Page 47: ...For Section 10 2 Test Equipment Needed 1 ms 50 V A DC CC Open Circuit Voltage Voltage Amperage Adjust Control R1 At Maximum 1 ms 10 V B DC CC Output 28 Volts DC 200 Amperes Amperage Range Switch S3 At...

Page 48: ...4412 Page 44 D502K 5 4 10 5 Filter Board PC6 Testing Information 803 208 192 998 Y Stop engine See Section 10 6 for specific val ues during testing Voltage read ings tolerance 10 Test Equipment Neede...

Page 49: ...ith respect to pin RC2 10 3 24 volt ac input with respect to pin RC2 10 4 24 volt ac output with respect to pin RC2 10 5 Contactor control circuit 24 volt ac input with contact closure to pin RC2 9 an...

Page 50: ...erving the LED s on LED board PC9 in control box Do not open the PC1 sealed case to service PC1 If PC1 is not working properly replace the entire PC1 module Be sure plugs are secure See Sec tion 10 8...

Page 51: ...Control switch S6 in Weld Terminals Always On position or place S6 in Weld Terminals Remotely Controlled position and connect remote contactor to remote receptacle RC14 Reset circuit breaker CB5 Check...

Page 52: ...TM 4412 Page 48 D502K 5 4 10 9 LED Board PC9 Testing Test Equipment Needed Be sure plugs are secure See Sec tion 10 10 for specific values during testing 1 LED Board PC9 803 208 192 226 A 1...

Page 53: ...ly to PLG13 5 LED lights if okay 6 Output on off LED 0 13 volts dc input with contactor off 2 volts dc input with contactor on To test output on off LED apply 2 volts dc to PLG13 6 and connect negativ...

Page 54: ...emove and in spect all three brushes Replace brushes if damaged or if brush is at or near minimum length 5 Slip Rings Visually inspect slip rings Under normal use rings turn dark brown If slip rings a...

Page 55: ...gth is in circuit Start engine and check GFCI1 and RC1 voltage If necessary change R3 connections until correct volt age is obtained at receptacles with out exceeding 4 6 amperes dc ex citer revolving...

Page 56: ...ry in Section 12 for connection information Disconnect F stator weld leads from Amper age Range switch S3 F stator exciter leads from termi nal strip 1T F resistor R3 leads F weld output terminal lead...

Page 57: ...th endbell 4 Rotor If engine must also be removed remove en gine from base mounts Reassembly Instructions Reinstall engine and generator parts as needed using torque values in table Reinstall upright...

Page 58: ...TM 4412 Page 54 D502K 5 4 Notes...

Page 59: ...following is a list of all diagrams for models covered by this manual To order a copy proceed as follows Model Serial Or Style Number Circuit Diagram Wiring Diagram D502K 5 4 LC110463 and following 2...

Page 60: ...TM 4412 Page 56 D502K 5 4 Figure 12 1 Circuit Diagram For D502K 5 4 Effective With Serial No LC110463 And Following...

Page 61: ...TM 4412 Page 57 D502K 5 4 206 628 A...

Page 62: ...C5 COM Figure 12 2 Circuit Board PC4 PC5 HF Filter Effective With Serial No LC110463 And Following 188 607 37A 17 30A 19B 19C 30C 30B 19A 37B 27 C4 C3 C1 C2 C5 C6 R1 RV1 Figure 12 3 Circuit Board PC3...

Page 63: ...Page 59 D502K 5 4 192 997 Figure 12 4 Circuit Board PC6 HF Filter Effective With Serial No LC110463 And Following 192 227 A Figure 12 5 Circuit Board PC9 LED Effective With Serial No LC110463 And Fol...

Page 64: ...A 3 COIL TO RANGE SWITCH 0036A PC8 PLG1 G1 TO PLG6 3 0036C RC6 3 S3 3 0037A 3 COIL TO RECTIFIER 0037A PC1 PLG8 G2 TO LEAD 37 FROM SR3 0037A PC3 TO BUS BAR 0037B PC3 TO LEAD 37 FROM PLG3 2 0038A T1 SEC...

Page 65: ...B RC1 3 TO SR1 AC 0102C SR1 TO C9 0102D RC3 4 TO C9 0102E R3 TO PLG3 4 0103A EXCITER STATOR PLG1 4 0103B PC1 PLG8 A1 TO PLG3 6 0103D RC3 6 TO RC1 4 0104A EXCITER STATOR PLG1 6 0104B RC1 6 TO F2 0105A...

Page 66: ...bel or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding genera...

Page 67: ...C position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Se...

Page 68: ...ng proper size weld cables with correct connec 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 fo...

Page 69: ...ollowing For OM 4412 206 995 TM 4412 March 2002 Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux...

Page 70: ...OWING Hardware is common and not available unless listed 86 96 4 6 3 105 109 Fig 14 5 108 107 FIG 14 3 106 104 110 111 98 91 101 FIG 14 2 103 12 9 7 8 10 102 94 95 91 1 2 12 11 13 14 19 18 82 84 83 85...

Page 71: ...412 Page 67 D502K 5 4 803 201 22 20 21 46 55 31 65 69 66 67 68 64 63 52 54 48 57 47 51 50 49 23 28 77 30 29 27 25 26 43 30 41 39 35 42 40 37 38 36 24 31 33 32 34 44 45 81 78 79 76 80 75 73 74 56 60 57...

Page 72: ...1 24 176104 Label Warning Falling Equipment Can Cause Serious 1 25 176230 Label Hot Exhaust Parts Do Not Touch 1 26 105734 Pipe Muffler Extension Elbow 1 750 Od 1 27 202629 Cover Radiator Access Stain...

Page 73: ...0 Adapter Engine Kubota V3300 See Figure 14 4 1 206907 Plug Assy W Leads Elec Kubota 1 207713 Thermostat 170f 76 5c W Gasket 1 206379 Flywheel Kubota V3300 1 74 198990 Adapter Oil Pressure Sender 1 75...

Page 74: ...Field Current Regulator 1 112 203260 Label Caution Do Not Use Ether 1 191819 Hose Sae 312 Id X 560 Od X 14 000 1 095636 Hose Sae 187 Id X 410 Od X 30 000 1 198584 Hose Sae 312 Id X 560 Od X 4 500 1 0...

Page 75: ...ge 40 Amp 800v 1 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 12 CR1 CR5 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin F...

Page 76: ...3 15 14 16 Figure 14 3 Panel Front w Components Description Part No Dia Mkgs Item No Figure 14 3 Panel Front w Components Figure 14 1 Item 107 Quantity 1 206212 Plate Screened Ident Control 1 2 20638...

Page 77: ...30a 250v L6 30r 1 010146 Clamp Nyl 625 Clamp Dia X 500 Wide 203 Mtg Hole 2 16 200910 Label Warning Electric Shock And Moving Parts CE 1 17 202641 Panel Auxiliary Power Stainless 1 18 601836 Nut 250 2...

Page 78: ...54 Seal Wire Univ 12p S 3row 1 196602 Plug Cavity 18 30 Position Cinch Connector 10 024103 Blank Snap in Nyl 750 Mtg Hole Black 1 120304 Blank Snap in Nyl 250 Mtg Hole Black 2 Optional When ordering a...

Page 79: ...21 605231 Screw M10 1 5 X 35hexhd Pln 8 8pln 4 22 194512 Washer Flat 1 250 Od X 406 Id X 7 Ga Thk Stal Pld 4 23 183387 Washer Cone 380 Id X 860od X 109t Stl Pld 4000lbs 4 24 198631 Nut M10 Hex Lock Nu...

Page 80: ...ONNECTION BOARD rectifier AC 1 2 188517 BUS BAR connection board 3 3 188135 ENCLOSURE rectifier 2 4 134201 STAND OFF support 3 5 PC3 201449 CIRCUIT CARD ASSEMBLY protection 1 6 188136 INSULATOR heat s...

Page 81: ......

Page 82: ...mer 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 distributor and...

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