Red-D-Arc RDA150T3 User manual

SERVICE MANUAL
WARNING
This equipment is designed and built with safety in mind. However, your overall
safety can be increased by your full understand followed by the content in this
manual.
Read this manual and familiarize yourself with its contents for your safety.
This equipment should only be operated and maintained by trained and qualified
personnel.
This equipment is designed for generating power source of electric tools, home
appliances and lights.
Do not install, operate or service this equipment without reading this manual and
unless you clearly understand this manual.
Specifications sub ect to change without notice.
File№ DGO-261_RDA150T3

This service manual is edited for authorized person to perform repair,
maintenance, and trouble-shooting to Diesel Engine Generator Welder,
Model Designation RDA150T3.
It is inevitably necessary to maintain and ad ust Red-D-Arc products
periodically in order to use fully and safely for long time. Therefore,
understand this service manual fully enough before use and proper
maintenance.
The information contained in this service manual describes equipment
available at the time of publication. While every attempt has been made to
give you the very latest information about your product, there may be some
differences between your equipment and the equipment described in this
manual. We reserve the right to make changes to equipments without prior
notice, and without obligation to make alterations to equipments previously
manufactured.
For service of the engine, refer to Workshop (Service) Manual provided by
the engine manufacturer described below.
MANUFACTURER
MODEL
KUBOTA V3800DI-TI

Table of Contents
1. Attention Statements ··············································································· 1
2. General Safety Instructions ···································································· 2
3. Specifications ····························································································· 4
4. General ········································································································ 5
4-1 Appearance ······················································································ 5
4-2 Dimension ························································································ 5
5. General Par ts Description ······························································ 7
5.1 Equipment ························································································ 7
5.2 Main Parts and Feature ········································································ 10
5.3 Main omponent ················································································ 10
6. Ser vice Data ······························································································· 13
6.1 Service Data ····················································································· 13
6.2 Generator ························································································· 14
7. ightening orque ······················································································ 17
8. Periodical Check for Engine ··························································· 19
9. rouble Shooting ························································································ 20
10. Wiring Diagram ············································································· 22

1
1. Attention Statements
・Technicians only who own enough knowledge and experience should work for
maintenance and operational check after maintenance.
・Before maintenance, always read this service manual as well as owner’s manual and
familiarize contents thoroughly before starting the service and maintenance of the
equipment for understanding of the equipment, safety instructions and cautions.
・ Throughout this manual are special attention statements.
A statement preceded by the triangular attention symbol and the word “WARNING”
contains information that should be acted upon to prevent serious bodily in ury.
A statement preceded by the triangular attention symbol and the word “CAUTION”
contains information that should be acted upon to prevent mechanical damage.
WARNING
CAU ION

2
2. General Safety Instructions
ELECTRIC SHOCK
NEVER touch the output terminals
during operation
NEVER touch the output terminal during
operation even though the breaker on the
load is being set at “OFF” position.
ALWAYS stop engine and make sure it
stopped before you will connect the loads to
the output terminals.
Suffocation by exhaust gas
NEVER run the engine indoors! Make
sure there is always good ventilation.
Fu es fro engine exhaust cause
serious injury.
ALWAYS operate the equipment in the
ventilated area.
When the equipment is used in a tunnel, hall
or any other indoor, the equipment for
ventilation must be used to prevent serious
accident caused by suffocation.
NEVER direct the exhaust fume to
houses nearby while considering the wind
flow direction.
Exhaust gas contains many harmful
elements that would cause affect to human.
Be free from suffocation when the
equipment is used in poorly ventilated area
such as inside of the building.
Entangled Injuries under
By Moving Componen t
NEVER reach and touch the moving
component during operation!
ALWAYS stop the engine during inspection
to prevent serious bodily in ury by entangled
accident under moving component.
Electric shock/Injuries/Burns
Never inspect equipment during
use .
Never serve and inspect when equipment is
being operated.
It may cause electric shock, in uries or
burns.
WARNING-Use good judgment
① NEVER run the engine when
transporting the equipment.
② ALWAYS stop the equipment
immediately if it suddenly begins to
violate or abnormal noise. Inspect for
broken, missing or improperly installed
parts.
③ ALWAYS keep the equipment as clean
as practical. Keep it free of loose
vegetation, mud, etc.
DO NOT make unauthorized
modifications or alterations to this equipment
of any of its components. YAMABIKO must
authorize alterations and modifications in
writing. Unauthorized modifications or
alterations may alter the equipment
operation and could eopardize personal
safety during operation.
WARNING

3
Work Safely
Generators and welders operate at very high
speeds and can do serious damage or
in ury if they are misused or abused. Never
allow a person without training or instruction
to operate and serve this equipment!
Attention to CAUTION LABEL！
Caution labels are placed on this equipment
and it would request special attention for
operation. Make sure to locate the labels
and understand the content of the caution.
・Check the caution labels is legible. Always
keep the labels clean or replace them when
worn or damaged
・Clean the labels by cloth, water or
detergent and never use organic solvent or
gasoline which may cause label peel off due
to adhesive solvent.
・Make sure to replace the labels when
damaged and illegible.
Before replacing the label(s), make sure to
place the new label(s) in the same position.
STOP the equipment immediately when
abnormal circumstances are noticed!
STSTOP the equipment immediately whenever
abnormal circumstances are noticed such
as unusual noise, smell, vibration and etc.
It may lead serious accident or fatal damage
of the equipment or properties.
Inflammables！
Keep the equipment far away from fire such
as cigarettes when refueling fuel, oil or
battery fluid.
NEVER operate or service the equipment
nearby fire as the equipment may catch
fire.
No Modification！
NEVER modify the equipment without
manufacturer’s advanced approval. .
It may lead serious safety issue and damage
the equipment.
Inspect the equipment before engine
start for operation and periodical inspection
without fail！
Make sure to serve initial check before start
engine and periodical inspection for safety
and longer life of the equipment.
CAUTION

3. Specifications
Model U it RDA150T3
Alternator
Ge erati g Type - Rotati g Filed, Brushless 3-Phase
Sy chro ous Alter ator
Rated Output kVA 150
kW 120
Voltage – Three phase V 208 / 480
Voltage – Si gle phase V 120 / 240 / 277
Amps
Three phase – 480V A 180
Three phase – 208V A
416
Si gle phase – 240V A
361 (zigzag)
Si gle phase – 120V A
361 x 2 (zigzag)
Rated Freque cy Hz 60
Wi di g - 3-phase, 4-wire
Star with eutral / Zig-zig
Power factor % 80
I sulatio class - F
Excitatio - Self-Excitatio (Brushless)
No. of poles - 4
Engine
Types - Vertical Water-cooled 4-cycle Diesel E gi e
Model (Ma ufacturer) - 6HK1 (ISUZU)
No. of Cyli ders (bore x stroke) (in. / mm) 6 ( 4.53x4.92 / 115x125 )
Co ti uous rated output kW 142
HP 190
Rated speed rpm 1800
Displaceme t cu.in. / liters 475.4 / 7.790
Combustio system - Direct Fuel I jectio with Turbo Charger
Cooli g method - Radiator
Lubricati g method - Forced lubricatio
Starti g method - Electric start
Fuel - Diesel
Lubrica t oil - CD class
Fuel ta k capacity gal. / liters 74 / 280
Lubrica t volume (Full) gal. / liters
10 / 38
Cooli g water volume gal. / liters
6.3 / 23.8
Starti g motor capacity V-kW 24 – 5.0
Chargi g dy amo capacity V-A 24 - 50
Battery - 105E41R x 2
Battery capacity V-AH 12(V) – 100AH
Unit
Le gth in. / mm 135.8 / 3450
Width in. / mm 48.8 / 1240
Height in. / mm 72.8 / 1850
Dry Weight lbs. / kg 6504 / 2950
I stalled Weight lbs. / kg 7187 / 3260
**Specifications subject to change without notice.
4

4. General
4.1 Appearance
4.2 Dimension
Unit in the drawings below is shows by mm.
5

6

. General Parts Description
5.1 Equipment
7

8

9

5.2 Main Parts and Feature
(1) Unit Serial Number
(2) Engine Serial Number
5.3 Main Component
10
Provide both serial number of unit and engine to your
local service shop for update parts and warranty
information.
Circuit Breaker
Feature: Protect electrical
circuit from damage by
overload or short circuit.
M
onitor Lamp
Feature: Light a monitor
lamp when equipment is
malfunctioned.
Volt Meter Selector Dial
Feature: ial to change
voltage.
Water Temp. Meter
Feature: isplay water
temp. in the radiator.
Fuel Meter
Feature: isplay volume of
the fuel left in the fuel tank.
Oil Pressure Meter
Feature: isplay oil pressure.
Emergency Stop Button
Feature: Engine stops when emergency by
pressing it. Turn it to clockwise to release
the button.
mpere Meter Selector Dial
Feature: ial to select the
output current.
Voltage djusting Dial
Feature: A dial to adjust a
voltage.

Right Side Door
Left Side Door
Terminal Rest
Feature: Relay terminal block of
the power output from the
alternator.
1
1
Fuel Drain Plug
Feature: rain the old fuel from the
fuel tank.
Oil Drain Plug
Feature: rain the old oil from the oil
tank.
External Fuel Inlet
Feature: Inlet to refuel from the
external tank.
External Fuel Return
Feature: Outlet to return fuel
from external tank.

Standard Accessory
① Owners Manual 1 copy
② Engine Instruction Manual 1 copy
③ Engine Warranty Manual 1 copy
④ Starter Key 1 set (2 pcs)
1
2
3
-
ay Valve
Position A (to use a built-i fuel ta k)
Positio the 3-way valve lever to UP ARD to use
fuel from the exter al fuel ta k.
Position B (to use a exter al fuel ta k)
Positio the 3-way valve lever to DO N ARD to
use fuel from a built-i fuel ta k.
Note: The 3-way valve lever is set at positio A at
delivery from a factory.
Position A
Position B
3-Way Valve
Lever
Note:
Do not remove the plugs when fuel is
supplied from a built-in tank. (when the 3-way
valve positions at position A.)
3
-
Way Valve
Feature: Valve to change fuel supply from a
built
-
in or external tank.

6. Service Data
ELECTRIC SHOCK
ARNING
Never touch the output terminal during operation to avoid electric
shock. Always stop the engine and remove the starter key during a
service maintenance.
Stop the engine before you will start any maintenance!
6-1 Technical Specification
Items Refere ce Value Note
I sulatio
Armature
wi di g 3MΩ or more DC500V
Megger Tester
Exciter field
Preheat time
Approx. 20 sec. with coola t temperature
-15℃(5 °F) a d approx. 1 sec. with coola t
temperature 30℃(86 °F)
Automatic
preheati g system
Mi . rpm at o load 1000±25 mi
-1
Max. rpm at o load 60Hz: 1800±25 mi
-1
Lubrica t oil pressure 0.2~0.6MPa{2.0~6.1kgf/cm²}
Coola t temperature 75~90℃ (167~194
°F)
Frame temperature limit withi 115℃ (239
°F)
Sealed beari g temperature limit withi 70℃ (158
°F)
Speed regulatio Mome tary withi 10%
Steady-state
deviatio withi 5%
Voltage regulatio
Mome tary withi 20%
Steady-state
deviatio withi 1.0%
Freque cy Idle: 33.3 Hz, Rated: 60 Hz
Variable voltage (60Hz) 400~505V at 60±0.1Hz
Protective device
1
Low oil pressure Worki g Pressure 0.1MPa{1.02kgf/cm²} E gi e Stop
2
High water temp. Worki g Temperature 105℃ (221
°F) E gi e Stop
3
iagnosis
E gi e Malfu ctio - -
4
Insufficient Battery
Charge
- Battery voltage: below 8V -
5
Over Speed
- above 2070 mi
-1
E gi e Stop
6
Boost
I take Temperature 85℃ (185 °F) -
1
3

6-2 Generator
(1) Exciting Amperage
Amperage fluctuates based upon the winding temperature. Following is for reference only.
Frequency/Rated Output Load Exciting Amperage (Measured)
3-Phase 60Hz: 120 kW No load 0.57A
Full load( power factor=1.0) 1.04A
(2) Resistance Value
Nominal resistance of the winding is tolerated within ± 10% at 32 °F( 220℃) of the ambient temperature.
The resistance must be measured by low resistance tester. It can not be measured by multi-purpose
tester cause of index error.
Generator Exciter (Measured)
Stator Rotor Stator Rotor
Armature Exciter Winding J－K Armature
Between
T1-T4, T7-T10
T2-T5, T8-T11
T3-T6, T9-T12
- -
0.048 Ω 1.574 Ω 14.96 Ω 0.185 Ω
[ olor ode]
(B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr)
Black
White
Red Green
Yellow
Brown
Blue
Orange
Gray
(3) Technical Specifications
Items
Article Method Condition to verify Criterion
Check before operation
Shape, ent, Blot
Visual
Inspection
No dent, blot and deformation
Coating No looseness
Joint Meet the criteria
Oil, Coolant Meet the required level
Wiring
Lead wires to be securely fastened
against
abrasion and damage to bring by
vibration
Grounding
Continuity Tester
“GROUN ING” is connected;
-with Engine (bolt for grounding)
-with Bed (bolt for grounding)
-with grounding for Receptacle
Continuity is to be confirmed
I
nsulation Check
Insulation Resistance
C500V
Mega
Tester
Main Breaker ON.
1-phase breaker (50A) ON
1-phase breaker (20A) OFF
isconnect one coupler from the
stator.
Voltage Selector: 480V (3-phase)
- Remove all output lines connecting
to “T10 & T11” in terminal rest.
- Remove the output line “T12” from
the terminal rest.
-Open a pc terminal in the output line
“U2” from the stator.
*Insulate all terminals after removal
Over 3MΩ
ielectric Voltage Tester AC2400V (1 sec)
Electric Current: 10mA
14

Items
Article Method Condition to verify Criterion
Insulation
Check
ielectric Voltage Tester
Connect “grounding terminal”
- with output terminal “L1”.
- with output terminal “L2”
- with output terminal “L3”.
- with initial excitation winding.
(Coupler marked with “J” or “K”.)
ditto
Monitor
Glow & Monitor Lamp
(OIL PRESS,
WATER TEMP,
ENGINE, AIR
FILTER & FUEL)
Visual
Inspection
Starter Switch
“RUN”
position
Coolant Temp:-15~50℃ (5~122°F )
Glow Lamp & Charge Lamp ON. IAG (diagnosis) lamp
OFF after it turns on for a while. Hour Meter is activated.
Engine is
running.
All monitor lamp OFF. Pilot lamp ON. Hour meter is
activated.
Protection Circuit
Emergency Stop
Engine is
running
Emergency stop switch ON and engine stops.
Water Temp.
Short-circuit red/black and black/yellow lines connecting
to a water temp. sensor. Overheat lamp ON and engine
stops.
Thermal Relay
Engine Stop Thermal relay is set at 3.6A. Breaker ON and thermal
relay RESET.
Engine is
running
Turn test trip lever to “TRIP”. Main breaker lever trips
between ON and OFF position.
Terminal Cover
Safety Feature
Open 3-Phase output terminal cover. Main breaker lever
trips between ON and OFF position.
Operational Check
Phase rotation
Phase
Rotation
Indicator
Rotate as arrow shows
AVR Adjustment AC Volt
Meter
Output selector switch is
set at 2080V (3-phase)
No Load
Voltage Adj. ial: Max
Frequency (Hz)
Output (V)
60 ± 0.1
253 ±1
*Adjust the Volt Adjusting
Volume in AVR. (#1)
3-Phase Output
(Comprehensive
Voltage Regulation)
Load Tester
Frequency
Meter
Wattmeter
Stop Watch
Engine Speed 1800 mi
-
1
,
E gi e Co trol Switch Setti g:
- Load Advance: OFF
- Regulation Mode: OFF:
Output selector switch is
set at 480V. (3-phase)
Output: 120 ±1.2kW
Voltage: 480+/-1V
Frequency: 60 ±0.1Hz
Power Factor: 1.0
Throttle Switch: RUN
% kW V A Hz
100
120+/-1.2 480±1
(1.04)
60 ±0.1
5 90+/-0.9
480±6
(0.88)
60±0.2
50 60+/-0.6 (0. 2)
25 30+/-0.3 (0.60)
0 no load (0.5 )
3-Phase Output
(Transient Load
Change Excursions)
Output selector switch is
set at 280V. (3-phase)
Output: 120±1.2kW
Voltage: 240+/-1V
Power Factor: 1.0
Throttle Switch: RUN
Refer to #2
1-Phase Output
AC Volt
Meter
Output selector switch is
set at 240/120V.
(3-phase)
Voltage: 240+/-1V
Frequency: 60±0.1Hz
No
Load
Receptacle
Voltage (50A) X-Y 240±3V
GFCI Receptacle
Output 120±2V
3-Phase Output
Voltage Adjustment
Output selector switch is
set at 480V. (3-Phase)
Voltage Max. (V) Voltage Min. (V)
over 504 below 408
Engine Speed
Adjustment
igital
Tachometer
Adjust the engine control
switch at no load.
Idle Speed (min-1) Engine Speed
Adjustment (Hz)
1000±25 below 50~above 63.
15

#1:
#2:
Mode Output Voltage (V) Setting Time Frequency (Hz)
Setting Time
Loaded  No Load
(Transient Max.) below 288 below 2 sec. below 66 below 8 sec.
No Load 240+/-3 - 60+/-0.2 -
No Load  Loaded
(Transient Min.) over 192 below 2 sec. over 54 below 8
Loaded 240+/-3 - 60+/-0.2 -
Use screw locking glue (recommended ThreeBond 1401C) over the VR
and VRE after adjusted.
VRE VRE
ＶＯＬＴ.ＡＤＪ
16

7. Tightening Torque
No Nome clature
Part to
be
tighte
Size Qty
Torque
Allowa ce
Nm(kgf/cm)
Refere ce
1 Drai Plug~Socket
Drai
Plug
M24
(fi e pitch) 1 68.7-88.2 (701-899)
Put a lubrica t to
O-ri g a d alig
it i to a groove.
2 Socket~Oil Pa Nipple ditto 1 49.1-58.8
(501-599) ditto
3 Cushio ~Bo et Screw M4x30 8 1.0-1.4
(11-14)
4 Pa el~Fro t Door
Nut M5 8 2.0-2.9
(500-571)
5 Stay~E gi e Bolt M10x30 8 39.4-58.0
(402-591)
6 Rotor~E gi e
(flywheel side) Bolt M10x30 8 44.2-53.9 (451-549)
7 Stator~E gi e Bolt M10x30 12
44.2-53.9
(451-549)
8 Bolt~Plate Nut M16 5 58.9-68.6
(601-699)
9 Termi al
Cover~Bo et Bolt M10x35 2 10.6-15.2 (109-154)
10 Radiator~Frame Bolt M12x50 4 20.8-30.4
(213-309)
U iformly tighte
the bolts.
11 Exhaust
Pipe~E gi e Nut M10 (fi e pitch) 8 30.5-45.1 (312-459)
12
Flex.
Tube~Exhaust
Pipe
Bolt M16x65 4 122.6-181.4
1251-1849)
13 Fuel Ta k~Frame
(bed) Bolt M8x70 2 -
There should be
o rattles i fuel
ta k.
14 Elbow~Valve Elbow - 2 -
Atte tio to the
directio for
i stallatio of the
elbow.
15 Valve~Frame (bed)
- - -
Atte tio to the
directio for
i stallatio of the
elbow.
16 Pipe~Fuel Strai er
Eye Bolt
M16x1.5 4 39.3-49.0
(401-499)
Atte tio to the
directio for
i stallatio of the
pipe. I sert the
packi g i to both
side of the pipe.
Put a lubrica t.
17 Fuel pomp~Frame
- - - - Put a lubrica t.
18 Fuel Pomp~Frame
- - - -
Atte tio to the
directio of the
fuel pomp.
19 Joi t~Oil Strai er Joi t G3/4 2 54.2-63.9
(553-651)
Atte tio to the
directio of the
joi t. Put a
lubrica t.
1
7